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The entire process
is evaluated for areas of waste/delay. These are such things as
redundant activities that can be combined, required activities that
are not performed and activities that are performed that are not
required. Each step in the "as-is" process should be look at from
the perspective of supplier/customer. Each activity should receive a
product from a "supplier." They should then provide some customer
value-adding activity to the product and become its supplier to the
next customer in line.
The team focuses on
the value added by each step in the process. During this analysis,
established policies and procedures must be challenged and
considered for possible elimination even if it might have been
looked upon as impossible in the past. Processes are full of steps
and activities that are looked upon as mandatory. However, how many
times have emergencies come up where we have quickly developed
alternatives to work around the bureaucracy of the established
process to eliminate steps, time and cost? We should consider making
these work around processes the rule and not the exception!
The team will next determine, for each area of waste/delay, one or
more causes and the overall root cause. Once root causes have been
established, the team identifies smarter, more creative methods of
performing the required tasks in the process. Some commonly used
techniques for this activity include brainstorming, force field
analysis, cause and effect diagrams, pareto analysis, benchmarking
the process with other companies, etc. Each improvement idea is then
evaluated to ensure appropriate assignment of responsibility in the
organization and to quantify the savings to be achieved or any
additional cost considerations. Once the improvement ideas have
been identified and quantified, the "as-is" flow will be updated to
provide a "to-be" flow showing the elimination of unnecessary steps
and bottlenecks and the overall streamlined process.
The next activity
is that of packaging the results into presentation format for
communicating and obtaining "buy-in" from those involved. Past "Red
Team" efforts have frequently resulted in voluminous final reports
that wind up collecting dust in a book shelf. Using a presentation
that is suitable for a variety of audiences fosters communication
and makes it easier to obtain the required upper management buy-in.
The presentation should include:
• Project Statement
or Issue
• Owner and Team members
• Interview List
• Scope/objectives/boundaries/goals
• Areas of Waste/Delay & Causes
• Prioritized Improvement List with Assignees
• "As-is" vs "To-be" Flow
• Savings in Time, Dollars, Step Reductions, etc.
• Implementation Plan
• Issues
• Follow-up & Feedback Process
• Lessons Learned for Future Reviews
• Acknowledgments
The initial
presentation is directed to the process owner. The owner decides to
proceed with all or a portion of the recommendations. Based upon the
owner's direction, the team then groups the approved recommendations
into logical releases for implementation. A "release" may be
composed of changes to processes, changes to software or any
combination of the two. From here, the team will deliver the
presentation to other management and members of the affected
organizations to inform, solicit support, encourage participation
and obtain buy-in.
Acknowledgments are
extremely important and can generally take two forms. The first is
to acknowledge both the process and the individuals who make it
work. We can usually find parts of a process that are already very
effective and efficiently operated. This activity should be
highlighted and the individuals commended for their efforts. The
second acknowledgement is toward the process review team. For the
time spent on the review these people have been taken out of their
normal roles and been tasked to change their thought processes from
departmental to total business. Their efforts should not only be
publicly recognized by the sponsor, but their performance on the
team should also be included in their next performance appraisal.
The final stage is
that of implementation. A separate implementation team may be
required if the necessary expertise is not present on the original
team. That is, if the release has software development involved, the
team needs to have programming and possibly data base expertise
added. There may also be less process experts needed for the
implementation. In either case, every effort is made to maintain
continuity.
The implementation
effort must be carefully planned and scheduled. Each improvement
idea is detailed as to who will perform what activities starting
when and for how long. The resultant plan should be loaded to one of
several available project management software packages. The plan
assures frequent follow up briefings with the owner and assignees to
both review progress and assess the effects of benefits of the
effort. As step implementations occur, the individuals involved
should be praised publicly for their efforts. Continuous
communication of the team's activities and successes is important.
This can take the form of articles in company newspapers or special
edition newsletters. Implementation of improvement ideas is not the
end of the process review. Rather, it is a prototype from which to
build and assure continuous improvements.
To be Continued
For balance of this article, click on the below link:
Lean Manufacturing Articles and go to Series 01
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