Flow Process Analysis – Improvement Opportunities

A great advantage of using a process flow chart is to identify non-value-added activities (NVAA) that can either be reduced or minimised, moreover, the process can be improved by looking at value-added activities (VAA), including simplifying the product design. Looking at changing value-added activities in a positive way may affect the non-value-added activities, which is a win-win situation. 

Although if any changes were to occur, they do require some sort of capital expenditure, and will also require time to implement, however, the payback of these changes will outweigh the expenditure in the long term.

If there are no changes to be implemented onto VAA, then minimising NVAA is crucial, i.e., minimising any waste is essential to success.

In order to start minimising waste of any kind, we need data, this is mandatory with all improvement strategies; as this will allow you to establish and measure the current situation. This data combined within a process flow chart provides everyone a clear concise view of the process.

After obtaining the data, we require an action plan, this will simplify the VAA and eliminate NVAA to improve the process. 

In order to do this, there are a few handy questions to ask yourself: can the activity be eliminated altogether? Can it be reorganised by moving it closer to another activity or combining it with another activity? Can the activity be improved by tooling? Can components be placed nearer to the activity? Can we improve communication to avoid waiting times?

Once the list of potential changes is finalised, a procedure within the plan must be made which will prioritise the actioning process. Priority usually goes to ideas that are the quickest, easiest to implement, and provide high levels of improvement. 

Once prioritised, the plan needs to set out the implementation method following the PDCA model. 

Learning Objectives:
 •    Identify the uses of a process flow chart
 •    Examine what questions can be asked to eliminate or minimise waste in activities during the action plan
 •    Assess what must be done with a list of potential changes, so the overall procedure is enhanced correctly, and most efficiently