Page 83 - Lean six sigma demystified

62 Lean Six Sigma DemystifieD

Purpose: Identify the waste, rework, and delay that can be eliminated from the
process.
Over time, processes become cumbersome, inefficient, and ineffective. This
complexity consumes more time and accomplishes less. Each activity, decision,
and arrow on the flowchart represents time and effort. From the customer’s
point of view, little of this time and effort adds value; most of it is non-value
added. From the customer’s point of view, delay and rework do not add value.
We can increase productivity and quality by simplifying the overall process—
eliminating delay and the need for rework.
Step Activity

1. For each arrow, box, and diamond, lists its function and the time spent
(in minutes, hours, days) on the value-added checklist (Fig. 2-9).

2. Now become the customer. Step into the customer’s shoes. As the
customer, ask the following questions:

• Is the order idle or delayed?
• Is this inspection, testing, or checking necessary?
• Does it change the product or service in a valuable way, or is this just
fix-it error correction work or waste?

Time
Spent Add Right
(hours, Value (not Changes The First
days, Cumulative inspection Product Time (not
Time
weeks, Spent or fix it or Service waste or
Activity, Decision, Arrow months) work) Physically rework)
A 1 1
B 2 3 Time Spent
3
3 25 3.5
3
3 3
3 2
3 2.5
3
3 1.5 2
3
3 Time Spent 1.5 Cumulative Time Spent
3 1
3
3 1
3 0.5
3 0.5
3
3 0 0
3 A B
3 Activity, Decision, Arrow
3
FIGURE 2-9 • QI Macros value-added flow analysis.