Process AnalysisUnderstand How To Identify Rework Loops,

Redundancies, and Bottlenecks

Look for Opportunities in the Process

• With a detailed map of the process, potential clues for possible causes of your issue can be seen.

• Some key pointers:

• Rework loops

• Redundancies

• Bottlenecks

• Handoffs

• Add cost and can give clues to understanding root cause

• Look for places where large amounts of work move back in the process to be fixed

• Many of these steps become an accepted part of the process

Rework Loops

• Many people are surprised when they map out a process to find that some things happen twice in the same process

• Look for limitations causing multiple entry of the same data, multiple handling of the same materials

Redundancies

• Places where your process is limited in the volume it can handle

• Often the result of specialization, task imbalance, or other restraints on capacity

• Will limit the ability of the process to get more done

• Constrain your process

Bottlenecks

• Can add time to a process

• Processes with multiple decisions and inspections can cause big delays

• Inspections are frequently added over time due to failure, sometimes the inspections continue to add cost long after the problem has been solved

Inspections & Decisions

• Generally create opportunities for something to be mishandled

• Create the opportunity for missed communication around requirements that can lead to additional inefficiency

Handoffs

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