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Business
Process Reengineering
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Manufacturing
Simulation
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PART VI.
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4. The Diagnostic Journey: In this stage, we begin to study the processes of interest. It is here that we document the processes using one of several different tools. These tools can be very simple ones such as those of Process Flow Analysis (PFA). This procedure categorizes every activity in a process using one of five symbols: operation, delay, transportation, inspection or storage. Other process documentation procedures include the Customer-Producer-Supplier Model, Matrix Methods, Process Analysis Technique (PAT), the Complexity Model, Entity Process Modeling, Real-Time Structure Analysis, Process Programming Approaches, Petri Nets and System Dynamics. A good reference on most of these various techniques is Melan (4). The task of documenting the process can be done manually or it can be carried out by computer using such packages as VISIO, AllClear, Arena (a system simulation package), STATEMENT or CASEWise (a business process documentation package with strong simulation capability). The method selected should be one with which the members of the committee feel comfortable. It should also be one that the members understand and see as being valid, transparent and credible.Once the process has been documented, it must be validated to make sure that all of the important steps have been included and that the documented process is an accurate representation of the real process. This can be done by either verifying the process with those who actually work with it or by actually following the real process through its various stages. After the process has been documented and verified, it must be then analyzed and characterized. One way of characterizing a process is to examine every step in the process and assign it to one of four categories: value-adding (it does something that increases value as seen from the perspective of the customer); waste-creating (the activity does not add value); non-value-adding but necessary (something that is needed such as a setup but which does not add value directly) and ? (the status of this activity has yet to be determined). Determining which category to assign each step can be facilitated by the "5 Whys" procedure. Before leaving this step, it should be noted that we are interested not only in identifying and characterizing the activities but in also identifying the times associated with the various steps. In documenting time, it is often useful to capture three pieces of information: expected time, optimistic time (how long should it take if everything goes right) and pessimistic time (how long should it take if everything associated with that activity goes wrong). These three points help us to determine the overall reliability of the process. (More information about this phase of analysis can be obtained by contacting the authors directly.) 5. Remedial Action: Now, we can begin to try to improve the process. When trying to improve the process, we are faced by two options: a complete redesign or fine-tuning of the current process. The option we pick is influenced by the information gained during the first step. A complete redesign is best achieved by using a "clean sheet of paper" approach. With fine- tuning, we must deal with the issues of "disposition" and "position." Disposition, which deals with how we will treat every step in the current process, presents us with four options: (I) Keep (we like what we are doing, we like how we are doing it); (2) Eliminate (the activity adds no value and can be dropped); (3) Combine (two or similar steps can be combined to eliminate time); and, (4) Rethink (we like the goal of the activity but not how it is being done). With Position, we are looking at whether we put the activity on the critical path (which affects overall lead time) or on a parallel path. 6. Resistance to Change: Changing processes creates resistance. To overcome this resistance, we can use two tactics: participation (which leads to acceptance and ownership) and time (with enough time, people will accept change). 7. Holding the Gains: Now that we changed the processes, we must prevent any fallback to either old "bad" practices or the old processes. To prevent this, new standards need to established. Training must be increased as well as the development of a new system controls. With the completion of this last step, the breakthrough has been achieved and the processes changed. Hopefully these changes will have eliminated the gaps that initially triggered BPR. With the set of the new standards, management is now ready to repeat this sequence of events again (to develop better and more effective processes). Concluding Remarks BPR is a potentially effective technique available for the firm interested in either developing a fundamental breakthrough by replacing their current processes with newer and more effective processes or in fine-tuning existing processes. To be used effectively, guidelines for its use must be established. What we have done in this presentation is to examine the entire concept of BPR and to develop such needed guidelines. We have also identified some but not all of the tools and techniques that can be used in successfully carrying out a BPR project. Hopefully, the information presented in this paper will help managers close their own gaps between what they want to achieve with BPR and the process of achieving these goals. STAY CONNECTED To stay current on manufacturing competitive knowledge, please subscribe to our weekly bulletin, "Manufacturing. Basics and Best Practices (MBBP)." Simply fill in the below form and click on the " subscribe button." We'll also send you our Special Report, "6-Change Initiatives for Personal and Company Success." All at no cost of course. Your personal information will never be disclosed to any third party. privacy policy Here's what one of our subscribers said about the MBBP Bulletin: "Great articles. Thanks for the insights. I often share portions of your articles with my staff and they too enjoy them and fine aspects where they can integrate points into their individual areas of responsibilities. Thanks again." Kerry B. Stephenson. President. KALCO Lighting, LLC Manufacturing
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