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Process
Analysis
We
will evaluate a specific process to:
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Look
for places where non-value added steps can be eliminated.
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Recommend
error proofing ideas to reduce or eliminate human error.
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Reduce
setup or changeover time.
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Integrate
cost effective technology to reduce labor and/or increase
production rates.
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Find
the root causes of quality defects and recommend solutions to
fix the problems permanently.
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Improve
process reliability and repeatability.
Step
1: Observe and Understand the Process
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What
are the critical inputs and outputs of the process?
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What
causes known variations in the process?
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Is
there a significant scrap or re-work rate and what is it?
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How
long is the setup or changeover time?
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How
long does the process take to complete one part and what is
the per unit cost of the process?
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What
improvement ideas have been tried in the past and were they
successful? If
not why not?
Step
2: Discuss Findings
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We
meet with company management to go over our findings.
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Any
misinterpretations are clarified at that time.
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Decide
what improvements to pursue first.
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Decide
how to quantify improvements.
(what will we measure to show an improvement)
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Establish
a time frame and goal for the improvements.
Step
3: Proposal
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A
written proposal documents process observations, what are the
goals of the improvements to be made, how the improvements
will be measured, the time frame and the cost.
Step
4: Put it together
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We
take care of getting what ever is needed to implement the
improvements we have proposed.
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If
the improvement involves new equipment or updating existing
equipment we work with your maintenance personal or outside
contractors to ensure the installation is done properly.
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The
new process or equipment is tried out and debugged before it
is introduced to the employees.
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