Nine Tips to Better Process Development

• Achieving exceptional results in process development requires mastering specific techniques designed to design successful, waste-free processes.
• Implementing the O1S2I3 model—observing current conditions, establishing stable standards, and methodically improving—prioritizes foundational understanding over premature capital expenditure on new technologies or rearrangements.
• The final critical element in process development is completing the Plan-Do-Check-Act (PDCA) cycle, which helps identify and resolve problems by rigorously testing the entire value stream as the launch approaches.

Achieving exceptional results in process development requires mastering specific techniques designed to design successful, waste-free processes. The initial step in effective process development is appointing a system architect who can oversee the process’s comprehensive and detailed aspects and ensure alignment with broader management systems. Emphasis is placed on developing not just individual processes but entire value streams that comprehensively meet stakeholder needs by defining what “good” means from their perspective.

The approach also involves managing to take time without rigidly designing processes around it, allowing for production flexibility. Implementing the O1S2I3 model—observing current conditions, establishing stable standards, and methodically improving—prioritizes foundational understanding over premature capital expenditure on new technologies or rearrangements. A strategic exploration of multiple alternatives early in the development process, through a 4-2-1 approach, facilitates innovative solutions by widening the scope of options initially considered before narrowing them down through successive refinement.

Moreover, automation is recommended as a tool, not a goal, to be employed only when it contributes to quality or safety outcomes that manual processes cannot achieve. The final critical element in process development is completing the Plan-Do-Check-Act (PDCA) cycle, which helps identify and resolve problems through rigorous testing of the entire value stream as the launch approaches. This systematic approach to process development helps ensure that new value streams are efficient and aligned with the organization’s overall goals.

Read the full article