Process Analysis 102 - ASQ Illiana

Process Analysis 102 - ASQ Illiana

Quality: The Basic Tool Kit Process Analysis 102 Process Analysis Tools 4 Tools in your Quality Tool Kit

1. F 2. F 3. M 4. S Process Analysis Tools 4 Tools in your Quality Tool Kit

1. Flowchart 2. F 3. M 4. S Process Analysis Tools When you want to understand a work process or some

part of a process, these tools can help: 1. Flowchart: a picture of the separate steps of a process in sequential order 2. Failure modes and effects analysis: a step-bystep approach for identifying all possible design failures 3. Mistake-proofing: the use of any automatic device or method that makes it impossible for an error.

4. Spaghetti diagram: a visual representation using a continuous flow line tracing the path of an item or activity through a process. Process Analysis Tools 4 Tools in your Quality Tool Kit 1. Flowchart

2. Failure Modes and Effects Analysis 3. M 4. S Process Analysis Tools When you want to understand a work process or some part of a process, these tools can help:

1. Flowchart: a picture of the separate steps of a process in sequential order. 2. Failure modes and effects analysis: a step-bystep approach for identifying all possible failures in a design, a manufacturing or assembly process 3. Mistake-proofing: the use of any automatic device or method that makes it impossible for an error. 4. Spaghetti diagram: a visual representation using a

continuous flow line tracing the path of an item or activity through a process. Process Analysis Tools 4 Tools in your Quality Tool Kit 1. Flowchart 2. Failure Modes and Effects Analysis

3. Mistake Proofing 4. S Process Analysis Tools When you want to understand a work process or some part of a process, these tools can help: 1. Flowchart: a picture of the separate steps of a

process in sequential order. 2. Failure modes and effects analysis: a step-bystep approach for identifying all possible design failures 3. Mistake proofing: the use of any automatic device or method that makes it impossible for an error 4. Spaghetti diagram: a visual representation using a continuous flow line tracing the path of an item or

activity through a process. Process Analysis Tools 4 Tools in your Quality Tool Kit 1. Flowchart 2. Failure Modes and Effects Analysis 3. Mistake Proofing

4. Spaghetti Diagram Process Analysis Tools When you want to understand a work process or some part of a process, these tools can help: 1. Flowchart: a picture of the separate steps of a process in sequential order.

2. Failure modes and effects analysis: a step-bystep approach for identifying all possible design failures 3. Mistake-proofing: the use of any automatic device or method that makes it impossible for an error. 4. Spaghetti diagram: a visual representation using a continuous flow line tracing the process path

Flowchart Process flowchart Process flow diagram Elements that may be included: sequence of actions

materials or services entering or leaving the process (inputs and outputs) decisions that must be made people who become involved time involved at each step process measurements

Flowchart Flow charts are simple diagrams To draw a flowchart: brainstorm the tasks and decisions Then map these out in flow chart format

Finally, challenge your flow chart Failure Modes and Effects Analysis FMEA House of Quality

FMEA A step-by-step approach for identifying all possible failures Design, manufacturing or assembly process or product or service

Failure modes = what could go wrong Effects analysis = how would it happen, how likely is it to go wrong and how bad would it be? What is FMEA?

1. What can go wrong? 2. What can be done to keep that from happening?

Why do FMEA? 1. When preventing problems is cheaper and easier than cleaning them up 2. Some things are too risky or costly to incur mistakes When to do FMEA?

1. Before theres a problem 2. During a projects lifespan 1. After theres a problem, so it doesnt happen again Failure modes and effects

analysis How to do FMEA 1. Gather your smart people together 2. Represent every area where a problem could occur 3. Use a worksheet to record the information

Mistake-proofing Poka-yoke Fail safe The use of any automatic device or method

that either makes it impossible for an error to occur or makes the error immediately obvious once it has occurred. 1. Eliminate the process step 1. Facilitate the correct 2. Replace the step action

2. If not, make detection easy When to do mistake proofing? 1. Where human error exists 2. At a handoff 3. When an error is costly

1. Self inspection 2. Source inspection 3. At the next step Mistake-proofing Elimination seeks to eliminate the possibility of error Replacement

substitutes a more reliable process Prevention engineers the product or process Facilitation makes work easier to perform

Detection involves identifying an error Mitigation seeks to minimize the effects of errors

Spaghetti Diagram Layout diagram A spaghetti diagram is a visual representation using a continuous flow line tracing the path of an item or activity through a process.

The continuous flow line enables process teams to identify redundancies in the work flow and opportunities to expedite process flow.

Process Analysis Tools PA Tool Definition Flowchart:

a picture of the separate steps of a process in sequential order. Failure modes and effects analysis: a step-by-step approach for identifying all possible failures

in a design, a manufacturing or assembly process, or a product or service. Mistake-proofing: the use of any automatic device or method that makes it impossible for an error to occur.

Spaghetti diagram: a visual representation using a continuous flow line tracing the path of an item or activity through a process. Quality: The

Basic Tool Kit Process Analysis 102 Allen K. Pratt, MBA, CIRM Hawkeye Consulting Advisors, Ltd. www.HawkeyeConsultingAdvisors.com

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