Process Analysis
Eng. Anil Ranasinghe
Anil 1
What Is Process Analysis?
• Helps Identify ‘Waste’
• Provides Objective Information
• Enables Process Improvement
• Applicable To All Processes
Anil 2
Tools of Process Analysis
• String / Spaghetti Diagrams
• Process Flowcharts
• Process Activity Maps
Anil 3
String Diagram
Before
~100 metres
Anil 4
String Diagram
After
~100 metres
Anil 5
What Is a Process Flowchart?
• Displays Processes Visually
• Shows How Activities Interact
A picture paints a 1,000 words
Anil 6
Implementing Process Flowcharts
• Identify Start & End Of Process
• Map EVERY Step
• Map Using ‘Facts’
- Direct Observation / Video
- Discussion With Staff Involved
- Gain Agreement
Anil 7
ASME Standard Symbols
June 1, 2018 Lab # 6: Method Study 8
Common Flowcharting Symbols
Process / Terminator
Activity
Document
Delay
Direction of
Flow Decision
Inspection
Anil 9
Flow Process Chart Symbols
Operation Delay
Transportation Storage
Decision
Inspection
June 1, 2018 Lab # 6: Method Study 10
Operation
Occurs when an object is intentionally changed in
one or more of its characteristics
Usually occurs at a machine or a work station
Drilling, Painting, Data Entry, Cutting, Sorting, etc.
June 1, 2018 Lab # 6: Method Study 11
Transportation
Occurs when an object is moved from one place to
another
except when the movement is part of an operation
or an inspection
Using elevator, carrying, moving with material
handling devices
June 1, 2018 Lab # 6: Method Study 12
Inspection
Occurs when an object is examined for identification
or is compared with a standard as to quantify or
quality
Examine the quantity or quality, read steam gauge on
boiler, detect the defectives
June 1, 2018 Lab # 6: Method Study 13
Delay
Occurs when the immediate performance or the next
planned action does not take place
Work In Process inventory waiting to be processed,
Employee waiting for an elevator, Waiting for
accumulation of a certain quantity for packaging
June 1, 2018 Lab # 6: Method Study 14
Storage
Occurs when an object is kept under control such
that its withdrawal requires authorization
Bulk storage of raw material, finished products
inventory, archived documents
June 1, 2018 Lab # 6: Method Study 15
Combined Symbols
Two symbols may be combined when two activities
are performed concurrently.
Operation and Inspection
June 1, 2018 Lab # 6: Method Study 16
Simplified Flowcharting Symbols
ACTIVITY • One or More Inputs
• One Output
• One or More Inputs
DECISION
• More Than One Output
Anil 17
Simplified Flowcharting Symbols
VA/NVA
DESCRIPTION
DISTANCE DURATION
Anil 18
Workshop 1 Do
Deburred - Parts Require yes Roll Parts
Flatpack Details Rolling
no
Example
Heat Treat
Flowchart
Required
yes
Heat Treat
Hardness Test
Precip.
Anneal Solutionise
no
Penetrant Flaw
Detect
Freezer
Sheet Metal Alocrom
Form Anodise
Paint
Tooling
Retrieval
& Delivery
to Sheet Metal Shop
End
Anil 19
Process Activity Mapping
• A systematic review of processes
• Enables decisions Based on fact
• More detailed than flowcharts
• Identifies the key area to tackle
Anil 20
Process Activity Chart
Record ALL process steps required to perform activity and determine if they are Value Adding [VA] or Non-Value Adding [NVA}.
Page ______ of ______. Include additional sheets as necessary.
Time to Do
VA or NVA
Lead-Time
Inspection
Movement
Operation
Distance
Delay
Store
Activity Remarks
Step
Anil 21
Process Activity Mapping
• Question Activities:
– ‘Is it Value Adding?’
– ‘Will the customer pay for this?’
– ‘Could we do without this activity?’
• Don’t Let the 1% prevent the 99%!
• 50% of Improvement Today is better than 100%
never!
Anil 22
Process Improvement
Eliminate
Reduce Combine
Simplify
Anil 23
Process Improvement
• Create the picture
– (String Diagrams or Flowcharts)
• Identify Non-Value Adding Activities
• Identify & Prioritise Activities
• Log ‘Actions’ and Responsibilities
• Monitor Achievements
• Start Again and Re-Map Activity
Anil 24
Process Analysis Activity
• Analyse the process of making a cup of tea
– Use the plan of the kitchen to create the string
diagram
– Use flipchart and post-its to create the process
map
– Fill in the activity charts
Anil 25
• Make a cup of tea
Anil 26
