Quality 4.0: Prepare and Refine Processes for Automated Operations

1. Quality 4.0: Prepare and Refine Processes
For Automated Operations
Daniel Zrymiak, ASQ Fellow, CSSBB, CMQ/OE, CQE, CSQE
ASQ Blue Ridge Section 1108
Webinar – Sept. 6, 2018

2. About Today’s Quality 4.0 Session
________________________________________________________
Daniel Zrymiak: ASQ Fellow, CSSBB, CMQ/OE, CQE, CSQE for ASQ Blue Ridge 1108
Quality 4.0: Prepare and Refine Processes for Automated Operations

3. Agenda
01 Overview
02 Refine The Process
03 Different Types of Automation Approaches
04 Savings and Takeaways
________________________________________________________
Daniel Zrymiak: ASQ Fellow, CSSBB, CMQ/OE, CQE, CSQE for ASQ Blue Ridge 1108
Quality 4.0: Prepare and Refine Processes for Automated Operations

4. Overview
Automation offers the potential to rapidly improve the speed
and predictability of processes, at lower costs and higher
rates of reliability and availability than human effort.
In order to correctly prepare a process for automation, certain
prerequisites must be completed
________________________________________________________
Daniel Zrymiak: ASQ Fellow, CSSBB, CMQ/OE, CQE, CSQE for ASQ Blue Ridge 1108
Quality 4.0: Prepare and Refine Processes for Automated Operations

5. Automation Overview
Prepare by capturing an initial baseline of current conditions
• Durations: How long do process steps take?
• Processing Time: How much time is spent by individuals doing value-added work?
• Waiting Time: How much non-value added time exists within Processing Time?
• Service Levels: What are the required service levels to be achieved?
Would Automation be Productive or Wasteful?
• What are the fixed and variable costs of automating your processes?
• Are processes addressing an essential need or demand?
• Would the organization benefit from reduced processing time?
• Do processes need to be scalable to handle increased demands?
________________________________________________________
Daniel Zrymiak: ASQ Fellow, CSSBB, CMQ/OE, CQE, CSQE for ASQ Blue Ridge 1108
Quality 4.0: Prepare and Refine Processes for Automated Operations

6. Refine The Processes
If there is a decision to automate, the process must first be
refined so that you don’t do bad processes faster
________________________________________________________
Daniel Zrymiak: ASQ Fellow, CSSBB, CMQ/OE, CQE, CSQE for ASQ Blue Ridge 1108
Quality 4.0: Prepare and Refine Processes for Automated Operations

7. Refining The Processes
Fix processes first before doing them faster
• Process reviews intended to reduce duration and preserve value-added steps.
Refinement
Category
Rationale
1. Simplify • Reduce Waste. Have clean and predictable outcomes.
• Remove opportunities for errors and variations
2. Standardize • Generate consistent results or outcomes at all locations.
• Track and Control events to Diagnose Problems.
3. Stabilize • Remove or streamline out problematic steps.
• Improve Reliability with fewer errors and hazards
• Reduce costly interruptions or required human monitoring.
4. Streamline • Identify and eliminate redundant steps.
• Redefine and shift Critical Paths from serial or sequential order to parallel.
• Reduce task quantity and end-to-end duration of the required workflow.
________________________________________________________
Daniel Zrymiak: ASQ Fellow, CSSBB, CMQ/OE, CQE, CSQE for ASQ Blue Ridge 1108
Quality 4.0: Prepare and Refine Processes for Automated Operations

8. Different Types of Automation Approaches
After these steps have reduced waste and variation, consider different types of
automation that may be appropriate to the context and situation.
________________________________________________________
Daniel Zrymiak: ASQ Fellow, CSSBB, CMQ/OE, CQE, CSQE for ASQ Blue Ridge 1108
Quality 4.0: Prepare and Refine Processes for Automated Operations

9. Automation Approaches
Summary of Automation Approaches
• Automation is not dogmatic and has many variations.
Approach Description Impact
1. Conversion
to Digital
Substituting paper-based
information for digital content.
Accept Artifacts from processes and
workflows
Reduce manual administrative work
2. Quick
Comparisons
and Decisions
Automate reviews and approvals
using clear and objective criteria.
Control reviews and authorizations are
needed to pass particular gates or stages.
Reduce backlogs and waiting times.
3. Combine
and
Consolidate
Combine and integrate components
Reuse and reduce repetitive
capturing and recording
Combine modules or objects making it easier
to manage and track,
Store and maintain associated data easier.
4. Rapidly
Repeat Tasks
and Steps
Complete repetitive tasks at
consistent and urgent paces.
Combine repeated tasks using automation
Deploy transactions or batch processes to
reduce manual effort.
________________________________________________________
Daniel Zrymiak: ASQ Fellow, CSSBB, CMQ/OE, CQE, CSQE for ASQ Blue Ridge 1108
Quality 4.0: Prepare and Refine Processes for Automated Operations

10. Savings and Takeaways
After automation has been prepared, compare
outcomes against the initial baselines to determine the
savings and benefits realized from the initiative.
Consider the Takeaways that justify similar automation
initiatives elsewhere.
________________________________________________________
Daniel Zrymiak: ASQ Fellow, CSSBB, CMQ/OE, CQE, CSQE for ASQ Blue Ridge 1108
Quality 4.0: Prepare and Refine Processes for Automated Operations

11. Savings Realized
Compare Savings Relative to Initial Baselines
• Savings can be realized from process refinements, automation, and
improved availability and service levels.
Savings Category Description Impact
Process Refinements Remove waste, non-value added
portions, non-standard
elements of the processes.
Processes are improved prior to
automation to be more predictable,
standardized, and consistently
performed.
Automation Using technology to complete
the processes faster than
manual effort.
Reduce duration, processing times,
and waiting times of processes.
Repurpose manual effort to more
complex and value-added activities.
Availability and
Service Levels
Improving the capability for
processes to be available on
request, and deliver within
service levels
Increased opportunity to take on new
demand and reduce impact to critical
path durations.
________________________________________________________
Daniel Zrymiak: ASQ Fellow, CSSBB, CMQ/OE, CQE, CSQE for ASQ Blue Ridge 1108
Quality 4.0: Prepare and Refine Processes for Automated Operations

12. Takeaways Yielded
Consider the Overall Improvements Yielded
• The preparation steps demonstrate Quality improvements, showcasing
Lean and Six Sigma techniques.
Improvement
Initiative
Description Impact
Process Improvement Improve processes to remove
elements and aspects causing
delays or deviations.
Achieve process gains using similar
techniques to 5S, Value-stream mapping,
and DMAIC.
Business Analysis for
Automation
Define the process and
automation solutions from
business perspectives
Improve cost, quality, speed, and schedule
Increase competitive solutions and serve
customers profitably.
Measurable Impacts Tangible gains in time saved,
consistency, conformance to
specifications and requirements,
and simplification.
Stabilized processes, reduced duration, and
completions with less technical and
physical demands on workforce.
________________________________________________________
Daniel Zrymiak: ASQ Fellow, CSSBB, CMQ/OE, CQE, CSQE for ASQ Blue Ridge 1108
Quality 4.0: Prepare and Refine Processes for Automated Operations

13. Preparing For Automation Summarized
Prior to automation, identify processes that have
inefficiencies, variation, errors, or redundant steps.
Simplify, Standardize, Stabilize, and Streamline processes.
Select automation based on the need and approach:
Conversion to Digital
Quick Comparisons and Decisions
Combine and Consolidate
Rapidly Repeat Tasks and Steps
Increase reliability and availability,
Reduce durations and waiting times,
Increase predictability and standardization.
. ________________________________________________________
Daniel Zrymiak: ASQ Fellow, CSSBB, CMQ/OE, CQE, CSQE for ASQ Blue Ridge 1108
Quality 4.0: Prepare and Refine Processes for Automated Operations

14. Questions?
Thank you for your indulgence and curiosity
Daniel Zrymiak dzrymiak.asq@gmail.com.
________________________________________________________
Daniel Zrymiak: ASQ Fellow, CSSBB, CMQ/OE, CQE, CSQE for ASQ Blue Ridge 1108
Quality 4.0: Prepare and Refine Processes for Automated Operations