Six Sigma Tool Navigator: The Master Guide for Teams

2017-07-07 02:10:07

AKA

Link Analysis, Assembly Flow

Classification

Changing/Implementing (CI)

Tool description

The construction of a work flow analysis (WFA) diagram is absolutely necessary to show how work actually (physically) flows from person to person, via groups and departments throughout the organization. Once completed, the work flow diagram will illustrate process flows, methods, information, and material movement.

Work flow analysis is often used as a problem-solving tool to identify process loops, cross-over, redundant moves, bottlenecks, and other inefficient or non-valueadding activities. It is of great assistance in understanding the existing process before improvements can be proposed in process redesign or reengineering efforts.

Typical application

To show the sequential steps involved in moving people, material, documentation, or information in a process.

To diagram or baseline work movement in order for a team to understand the current work-flow sequence.

To illustrate a system's inefficiency.

To identify and eliminate illogical process flows.

Problem-solving phase

	Select and define problem or opportunity
→	Identify and analyze causes or potential change
→	Develop and plan possible solutions or change
→	Implement and evaluate solution or change
	Measure and report solution or change results
	Recognize and reward team efforts

Typically used by

	Research/statistics
3	Creativity/innovation
	Engineering
4	Project management
2	Manufacturing
	Marketing/sales
5	Administration/documentation
	Servicing/support
	Customer/quality metrics
1	Change management

links to other tools

before

Facility Layout Diagram

Fault Tree Analysis (FTA)

Symbolic Flowchart

Gozinto Chart

Cycle Time Flowchart

after

Process Analysis

Failure Mode Effect Analysis (FMEA)

Action Plan

Decision Process Flowchart

Consensus Decision Making

Notes and key points

The sequence of flow can be shown as numbering sections of the flow path as shown . Other process paths can be encoded as or .

Step-by-step procedure

STEP 1 The team identifies functions and responsibilities of the work-flow process to be analyzed. See example Picture Frame Assembly.

STEP 2 The second step is to obtain a current floor plan and to "walk" the flow of the selected process. Mark up the floor plan displaying the basic "as is" flow. For repeats or different process phases, use different color markers. Timing the process at various stages will provide additional data: the cycle times of tasks, movements, and delays. The resulting diagram is sometimes referred to as a "spaghetti diagram" because of the multiline crossover appearance.

STEP 3 The team then performs an analysis of the current process and recommends a first draft of equipment rearrangements and work flow changes to reduce or eliminate process steps.

STEP 4 Step four requires team consensus to be reached and a presentation given to process owners and other interested parties.

STEP 5 Date the completed work flow analysis diagram.