What’s the value of process improvement? One way to look at it is by examining the reason for having a quality system in the first place. Let’s start by understanding the basics of six sigma, which define the maturity level of an organization’s management system. By that, we don’t just mean just a quality management system, but your entire system of management.

Sigma Levels

• 1 sigma = 67% error rate (or “2 out of 3 transactions are in error”)
• 2 sigma = 33% error rate (1 out of 3 transactions in error)
• 3 sigma = 6.7% error rate (1 out of 15 transactions in error)
• 4 sigma = 0.63% error rate (1 out of 160 transactions in error)
• 5 sigma = 0.02% error rate (1 out of 4,300 transactions in error)
• 6 sigma = 0.00034% error rate (1 out of roughly 290,000 transactions in error)

We define a system as “in control” when an organization’s processes exhibit a “3 sigma” (6.7%) or lower error rate.  If your organization has not defined its processes, effectiveness criteria, and competencies, it’s more likely that you’re at a 1 or 2 sigma level.  In order to achieve the “3 sigma” level, your company must consistently make no more than 6.7 errors per hundred — that’s a 93.3% success rate.

“Improve constantly and forever the system of production and service,
to improve quality and productivity, and thus constantly decrease costs.”
From W. Edwards Deming’s “Fourteen Points”

Are You Operating at a 93.3% Success Rate?

Let’s say you see 60-70% as normal, which is about 2 sigma (66% success). The “delta”, or difference, between 2 and 3 sigma is about 27%. We believe that by adopting a quality process improvement program, you should see your success rate rise from 66% to 93%.  That’s a 41% improvement over your current rate! What organization wouldn’t be interested in that?

Once you hit 3 sigma, your next goal is to improve to a 4 sigma level, then 5 sigma, and finally 6 sigma (which is as close as you can realistically get to “zero defects” in most operations).

Now quantify the benefit.  What is 27 percentage points of success worth to your customers? The cost of implementing a six sigma process improvement program is small compared to the benefits to your customer (and, of course, to your bottom line). Process improvement practically guarantees customer retention, and can lead to customers advocating for you.

But if that’s not for you, don’t implement a quality program. Learn to live with a 2 sigma error rate — and hope your customers can live with it, too.

Lean is a way of thinking about quality, your employees, and how you use your resources to deliver your product or service to your customers in the smoothest, most predictable, and easiest way.  Six Sigma, on the other hand, is a process model used to separate common cause variation from special cause variation in order to reduce such variation, which, in turn, improves your process performance.

So, which do you use? Lean? Or, Six Sigma?

When Do You Use Lean?

Lean thinking can be used to reduce obvious waste.  What waste is obvious?  There are eight common wastes that are the most obvious and, therefore, are the easiest to remove from your system.  These are the “low hanging fruit” on your quality tree. Lean can be rolled out relatively easily and implemented company-wide.

Lean is a good starting point for companies looking to build a new quality system.  Lean is fast — small projects can be completed in days, or even hours.  Most Lean projects require little investment beyond people to implement the project.  You can use your regular employees on the project, giving them a little bit of Lean training to get started.

When Do You Use Six Sigma?

Six Sigma is best for problems where the solution is not obvious.  Six Sigma is a five-step process model:

• Design,
• Measure,
• Analyze,
• Improve, and
• Control.

The DMAIC model is how scientists solve problems.  They collect data, apply statistical analysis, and isolate the problem.  Then, they analyze the data until they find correlations, test possible solutions, and solve the problem.

Some Six Sigma projects can take as few as three months, while others require 12 months or more to complete.  Six Sigma requires technical experts (“black belts“) trained in the tools, statistics, and solving problems.  Six Sigma works best on isolated problems and can take years to implement company-wide.

Lean can be used at any point in time but is, perhaps, best used to implement a quality culture of continuous improvement.  Lean is a great starting point for building a quality system, since it’s easy to get started, projects are quick, and results can be obtained fast.

Six Sigma is better after a quality program is under way and employees have become accustomed to improvement.  Six Sigma is better at large-scale, expensive problems that you can collect a lot of data around.  Six Sigma is a mature quality approach that requires discipline, trained individuals, and big problems.

My suggestion is to start with Lean and build an improvement culture.  Then, after years of Lean training, implementing lean projects, and resolving the more obvious wastes in your organization, you’ll be ready for a more mature program like Six Sigma.  Some have now started to call this “Lean and Six Sigma”.

So, it needn’t be a case of “either…or”. Instead, it may be a case of the whole being greater than the sum of the parts. Lean and Six Sigma, apart from one another, are very good quality improvement tools. Together, Lean and Six Sigma are great! (Sort of a yin-and-yang, I suppose.)

Try “Lean and Six Sigma”. Let us know how well it works for you.

When we talk about helping companies obtain ISO 9001:2008 certification, people often ask us, “Why does our company need to be ISO 9001 certified?” Good question. ISO 9001 is the quality management system (QMS) standard and it produces numerous benefits for any company willing to go that route. So, why should your organization obtain ISO 9001 certification?

1. Meet Customer Requirements

Many companies want to get ISO 9001 certified just to satisfy one customer requirement. The customer states that it will only do business with vendors that are certified as ISO 9001 compliant, so to get (or keep) the business they need that certification. The problem with these companies is that they’re looking for a short-term payoff.  They see nothing but that one benefit — we need money– and ignore the long-term benefits, like “if we keep the customer well satisfied, they will want to come back again and again”.

They don’t embrace the concept of quality through continual improvement. They don’t understand that continued customer satisfaction is the ultimate goal of a QMS. In other words, these companies haven’t “bought into the program”. See, you may obtain a piece of paper (that ISO certificate) that claims ISO 9001 certification without seeing much actual quality or improvement. Focusing only on that one benefit — your immediate gain — without putting the customer in front will end up costing you much more in the long run. Hopefully, some of the quality management system ideas may rub off and eventually stick…but wouldn’t you rather have a plan than trust to luck?

2. Get More Revenue and Business from New Customers

Once you earn your ISO 9001 certification, you can advertise your quality certification and respond to requests for quotes (RFQ) from companies that make ISO 9001 certification a “must-have”. ISO 9001 certification can open up new markets you were virtually unable to do business with before your certification.

3. Improve Company and Product Quality

A quality management system standard is all about quality (really!) so, of course, one result of adopting a QMS should be an improved level of quality for the entire organization — every process, and every product. There are many definitions of “quality”, but Philip Crosby and Joseph Juran provide two of the best. Crosby defined it as “conformance to requirements”; Juran called it “fitness for use”.  A well-designed, effectively implemented ISO 9001 Quality Management System will put your company on the Road to Quality.

4. Increase Customer Satisfaction with your Products

Quality means whatever you produce will work as your customers expect. You will meet not only their stated requirements — you will meet more of their implied requirements, too.

Quality also means far fewer complaints and doing a better job of resolving those you do.  If your quality management system is working correctly, you should know what your customers expect and you should be providing it, resulting in increased customer satisfaction.

5. Describe, Understand, and Communicate Your Company Processes

The ISO 9001 QMS standard requires that you identify and describe your processes using business metrics, the purpose of which is to better manage and control your business processes.  Quality objectives form the center of your system.  Metrics are used to understand and communicate your system’s performance relative to your quality objectives.  If you make an honest attempt to conform to the requirements of ISO 9001, you’ll learn more about your business.

6. Develop a Professional Culture and Better Employee Morale

Implementing an ISO 9001 Quality Management System can empower employees. Your QMS will provide them with clear expectations (quality objectives and job descriptions), the tools to do their job (procedures and work instructions), and prompt, actionable feedback on their performance (process metrics). The result? An improved company culture and a more professional staff!

7. Improve the Consistency of Your Operations

What is consistency? Well, one way to think of it is “decreased variation”.  Reducing the variation in your processes is the definition of consistency. Is your customer better served by you supplying them with a consistent product — same dimensions, same weight, same tolerances, same output every time — or by your products being unpredictable and “all over the place”? (I hope you’re not thinking too hard on this.)

Of course, they won’t accept variation, and neither should you! And how do you decrease variation?  Increase control of your processes!  Control comes from having a clear target to shoot for (objective), collecting data on the process (metrics), and understanding how to adjust the process (procedures and work instructions) to maintain the target output.  If your ISO 9001 QMS is working, you should be increasing operational…and product…consistency.

8. Focus Management and Employees

We’ve discussed quality objectives, metrics, and procedures used within an ISO 9001 Quality Management System. Having the right objectives, metrics, and procedures, management and employees should be able to focus better on what’s important.  Yet, this isn’t always the case — it’s easy to lose focus over a period of time.

The ISO 9001 QMS has a way to ensure the company stays focused, and that’s quality auditing.  Internal audits, registration (and surveillance) audits, and self-process audits. ISO 9001 requires that the company periodically audit its quality processes. Regular process audits and as-needed audits, when done correctly, provide the objective feedback needed to correct any deviations from the quality path and keep the company focused on its goals.

9. Improve Efficiency, Reduce Waste, and Save Money

An ISO 9001 Quality Management System isn’t perfect; no process and no one is perfect.  (Why else would the standard devote a clause to “continual improvement”?) A well-run QMS does enable your company to approach perfection.  As your processes improve, become more consistent, and you achieve your target objectives with greater regularity, you will see tangible results. Your process waste will decrease, for one.

Waste is money lost forever. Waste results from poor quality and inefficiency.  Inefficiency results from variation and inconsistent processes.  Reduce variation, improve consistency, and you’ll have less waste…and more money.  It’s that simple!

10. Achieve International Quality Recognition

ISO 9001 is a worldwide standard administered by the International Organization for Standardization (ISO), based in Switzerland. ISO 9001 is currently in use by close to one million organizations around the world!  It is truly a world wide standard for quality! Obtaining ISO 9001 certification puts your company in a very select group.

Why Should Your Organization Obtain ISO 9001 Certification?

Recapping the article, your company’s certification to ISO 9001 will help you:

1. Meet customer requirements;
2. Get more revenue and business from new customers;
3. Improve company and product quality;
4. Increase customer satisfaction with your products;
5. Document, understand, and communicate your company processes;
6. Develop a professional culture and better employee morale;
7. Improve the consistency of your operations;
8. Keep management and employees focused on quality;
9. Improve efficiency, reduce waste and save money; and
10. Achieve international quality recognition.

To learn more about improving your processes, attend our How to Create Well-Defined Processes Class, coming this spring to our St. Louis, Missouri, offices.

This week, I responded to an e-mail from a Bizmanualz reader who asked the simple question: How do we get to best practices faster? They wanted to know how best to use our products and services to address feedback from their sales department — that their processes are too long and, therefore, hamper sales. Bizmanualz will engage to whatever extent suits a customer’s need and budget. There are three options to choose from:

1. Buy whatever of our published products that you think you need or that we might recommend;
2. Start with our introductory process optimization services (outlined below); or
3. Buy the CEO series and contact me to buy two days of training to help you get started on your own.

Get coaching and personal service with our process review (option #2). Current pricing is shown in our shopping cart. Contact me for this service:

Review your current process. What are you doing now, and what do you want to improve? Here, we clarify your current work process so that we can measure improvement.

Compare your current process to Bizmanualz best-practice processes. No need to re-create processes when we already have them. We will update your processes to our best practices, saving you the trouble and expense of doing it yourself. Streamlined process maps are simple to understand and easy to implement.

Define the goals of your improvement and provide a roadmap for implementing change. Some example improvement goals:

1. Simplify the process so that they will be used by employees;
2. Increase the number of sales leads from the level identified in the current state; and/or
3. Increase the number of leads converting to sales or other desirable actions, such as signing up for a newsletter, obtaining a sample product, or requesting contact.

When you employ Bizmanualz to lead your improvement project, we customize a process for you from our extensive library of best-practice processes. Best practices are included. This saves you time and money on research and development. Our approach is to identify incremental improvements that involve and can be sustained by your current staff. Improvements are realistic, achievable, and sustainable so they’re achieved consistently and benefits add up fast.

Process Implementation Phase

I’ve described the process review engagement where the scope and pace of improvement is set.  Implementing the improvements is the next phase.

In the follow-on process implementation phase, Bizmanualz processes are delivered in all the formats — with the checklists and forms — that your people will use to follow through and practice the improvement. For the do-it-yourself-er, most of the process map formats and examples discussed here are described in a recent Bizmanualz article and commentary series, starting with “What is a Process Map?“.

A Bizmanualz quality consultant, with supporting quality engineers, writers, and communications professionals, will customize maps, job aids, and other tools for your project.  Read about the types of process maps and other tools we deliver on our site. The do-it-yourself-er can also read about project management tools and use them to manage their own project.

Anyone can comb through our manuals-product web site and select individual policies, procedures, and forms manuals or they can choose collections such as the CEO Company Policies and Procedures set.  Most CEO Series customers will benefit from a day or two of training and review, where we’ll introduce your employees to the books and tools in the CEO series and show them how to get started.

Contact me, Dan Davison, for more information about training to use the CEO series product.  Do you have comments? How can we help? Please write to me directly, or leave your comments below.

Thank you.

In Sarbanes-Oxley compliance your SOX policies and procedures have the same purpose as with ISO 9001 policies and procedures, to provide a foundation for improvement.  Sarbanes-Oxley is not a quality standard so why the need for improvement?

First, Sarbanes-Oxley (SOX Section 302 and 404) requires that your financial reports contain accurate information from controlled accounting and financial processes.  Second, signing executives have to report on the effectiveness of the company’s internal controls and disclose any significant deficiencies in the design or operation of those internal controls that could affect the company’s financial reports.

ISO 9001 uses terms like effectiveness and deficiencies too.  Only the focus is on continuously improving effectiveness and identifying non-conformances that do not conform to planned arrangements.   Sounds pretty similar to SOX compliance.

SOX Policies and Procedures Provide a Baseline for Improvement

SOX policies and procedures are used to build consistency, communicate SOX internal controls, and provide a baseline for SOX improvement.  This is done by indentifying a target performance (policy) and communicating a series of actions (procedure) to achieve the target. Risks are areas for mistakes, fraud, or abuse.  Internal controls are responses to mitigate indentified risks to the policy and procedure. 

For example, an accounts receivable policy might be timely invoice collection.  Your procedure consists of the steps to ensure a timely invoice collection.  Risks include an accounts receivable clerk taking cash, misapplying collections, or not collecting at all.  Internal controls could include: segregation of duties, cash application controls, bad debt reserves, credit policy, credit approval process, and so on.  Each control counters one or more identified risk to the accounts receivable procedure. 

But let’s say we missed a few risks, now what?  If it is determined to be a significant deficiency then you would disclose the risks that you missed and work on improving them.  With SOX policies and procedures like this, you are Sarbanes-Oxley compliant.  You have reported on the effectiveness of your controls and disclosed known deficiencies, just like with ISO 9001.  Sarbanes-Oxley compliance and ISO 9001 conformance are pretty similar in their implementation.

Bizmanualz Accounting Policies Procedures Manuals serve as a model, or framework, for your own SOX policies and procedures.  Save time with the CFO Accounting Policies and Procedures Manuals set, which contains 239 procedures you can use to address Sarbanes-Oxley compliance with the ten accounting cycles.

Simplifying procedures is a great way to save money and at the same time prepare for growth. By simplifying your procedures, you can cut waste with confidence that you are not cutting essential value-added services customers want to buy. Simplifying procedures prepares your company for growth because it streamlines your operations, documents them, and thus makes it much easier to replicate your operations at another location.

A new operation based on proven procedures is easier to manage because you can evaluate its performance against known metrics. And should the metrics indicate a need for adjustments-typical when rolling out a new location-staff will have procedures in place to affect needed changes. This significantly reduces the risk of opening a new location.

If you want to learn more about how you can save money and prepare for growth, check out our consulting pages. We can help you simplify procedures faster and more efficiently than you can do it yourself because we are continuously writing, publishing, deploying and updating policies and procedures. Our latest procedures represent lessons learned by our thousands of world-wide customers. Developed according to international ISO standards, Bizmanualz procedures move you further, faster. Save time. Why reinvent the wheel?

Check out our consulting pages. Or call me right now. Bizmanualz can help you save money and grow today. Contact: Dan Davison, Vice President Sales & Marketing, Bizmanualz, Inc. tel. (314) 863-5079 x23, Dan@Bizmanualz.com.

Among the top ten reasons that managers give for why their company’s policies and procedures don’t work is that “Employees don’t use them.” When procedures aren’t used, you may wonder why you bothered writing them. Did you waste your time? When procedures are written but not used, lessons that have been learned are forgotten. Mistakes that were corrected on paper long ago are made over and over again. Continuous improvement gives way to continuing problems and waste.

Waste costs money.  Yet, when organizations don’t follow their own core procedures, it’s hard for them to know what works and what doesn’t, so improvement evades them. They risk quality problems and customer disappointment. Customers may defect to competitors. Revenue may suffer.

When even core procedures are not used, you risk not complying with health, safety, and environmental regulations. That can endanger employees and gain unfavorable notice from auditors and regulators, further distracting you from using best practices and making continuous improvements.

Why aren’t your policies and procedures used?

When we hear employees say that procedures are getting in their way rather than helping, we usually find that procedures are too numerous, too long, poorly written, hard to follow, and/or hopelessly complex.  Writing and development problems are the chief reason that policies and procedures suffer such deficiencies. (See our web site for several articles explaining how to avoid and overcome procedure writing and development problems.)

How Bizmanualz Estimates Your Policies and Procedures Project

When companies come to Bizmanualz with poorly written policies and procedures, we typically recommend reducing and simplifying what they have today. Typically, we can cut from 30% to 60% of their documentation load, reducing the cost and complexity which at the same time lessens employees’ objections.

We can recommend an approach for your policies and procedures improvement project based on your answers to the following questions:

• How many procedures do you have today within the scope of the improvement project?
• Send us two or three sample procedures in MS WORD or PDF format. Let us know what format you want for the final procedures.
• What industry are you in?
• List the countries in which the procedures will be used. List each of the languages into which the procedures need to be translated (if any).
• Who is the lead regulator for your industry in each of the countries where the procedures will be used? Provide a link to the regulator’s web site and on-line regulations if available. List any other regulators that are likely to review or audit your procedures.
• Mention any quality standards that you are using or plan to use within 24 months.

Pictures and Graphics Help Bridge Cultural Gaps

If the procedures will be used in more than one country, we typically recommend replacing text with graphics, illustrations and pictures. Graphics are interpreted more consistently across cultures, which drives uniform interpretation and more consistent usage of procedures.

Page for page, graphics are more expensive to produce than written material. But a single graphic may eliminate a lot of pages of written material, mitigating the cost of development.  Most companies consider investment in graphics worth-while because:

• Procedures are used more consistently
• Compliance improves
• Injuries and work disruptions decrease.

Your Budget Considerations:

If Your Budget is Less than $10,000 US:

At budget levels less than $10,000 US, we would typically recommend training for your in-house procedure-writers on how to write more effective procedures. The training is similar to our Well-Defined Processes training, but emphasizes authoring procedures. After the training, your in-house team rather than Bizmanualz would apply the principles and update your procedures. Depending on the experience level of your procedure-writing team, more than one training event may be required.

If Your Budget is $10,000 to $30,000:

At budget levels above $10,000, Bizmanualz relieves your team from the production responsibilities, and provides the man-hours and expertise to update your procedures more quickly than most companies can train and do it on their own. At budget levels in this range, Bizmanualz:

• Evaluates the content and format of each of your existing procedures within the scope of the project
• Provides you with our written critique
• Provides a visual storyboard outlining the specific changes
• Drafts the procedures for your review
• Completes the graphics and reviews them with you
• Provides one revision to text and graphics, incorporates your comments
• Completes and delivers the procedures.

Projects above $30,000 are larger projects in scope; they might require deployment in more than one location, translation, optimization, or a lot of information graphics.

Larger projects may include procedure implementation of your procedures with your employees to make sure that they perceive value and use the procedures.  This may include additional buy-in training for your in-house procedures team on how to build and maintain support for your policies and procedures project.  You may need other communications tools such as job aids or videos that are not strictly considered procedures, but which nonetheless help workers apply the procedures consistently.   Process procedures optimization may require implementing lean, ISO or quality systems.

You can control the scope and budget of your project by:

• Controlling the number of procedures
• Working in phases, and reducing the scope of the current phase.
• Creating fewer language translations and limiting the number of geographies where the new procedures will be used.
• Using fewer graphics and more text.

If you would like Bizmanualz to estimate your policies and procedures project, please send us the information listed above under ‘How we Estimate Your Policies and Procedures Project.’ Don’t forget to send us samples of your current procedures. We will recommend an improvement approach that will increase compliance, safety and communication.

Contact: Dan Davison, Dan@bizmanualz.com, tel. (314) 863-5079 x23, Bizmanualz, Inc.

Why should you implement a lean kanban system?  How can you beat a simplified production system that costs less, satisfies customers more, and takes the headaches out of management?  A kanban is system of signals used in lean to balance the flow of work, materials, and people to get a job done.  Kanbans are used within agile software development, manufacturing, service deployment, construction, and just about anywhere people are implementing lean systems.

Let’s look at the top ten reasons for implementing a lean kanban system.

1. Visualizes your work

A lean kanban translates your production planning into visual kanban boards, kanban cards, or electronic e-kanban signals. A value stream map is used to understand your kanban needs.  Workers can all see what the current production plan is easily and quickly by reading the visual kanbans.

2. Reduces your Work In Progress (WIP)

A Kanban is built by balancing your individual work cells to the pull of customer demand using kanban signals.  Lean balanced flow reduces WIP created by batch sizes that are larger than customer orders.

3. Moves your work along Steadily

A balanced flow is achieved by understanding the takt time or rhythm of customer demand and then adjusting individual work cell batch sizes to achieve the steady balanced product flow.  Your workers jobs are now even, steady, set to a comfortable frequency that satisfies customers and management.

4. Improves your work flow

A steady balanced lean product flow is a great lean process improvement over traditional chaotic systems made of large batch sizes.  The whole system operates together as a team reducing employee stress levels and adding a calm to the organization.

5. Releases your work on demand

New orders trigger the system to produce the next batch.  A balanced system only produces enough products to fulfill customer demand and hence only releases orders on demand.

6. Simplifies your production planning

Your production planning is reduced to adjusting the kanban size as market conditions change.  A steady balanced manufacturing flow sets the order turnaround time eliminating expedited orders and special rush jobs that are the bane of traditional production planning.  In effect, all orders are expedited when you balance the flow to customer demand.

7. Eases your purchase planning

Purchasing becomes balanced with production kanbans and can be simplified even more using e-kanbans that automatically send purchase orders direct to suppliers.

8. Increases your customer satisfaction

The real goal of a kanban is to understand what all customers demand and then focus your production on that customer demand.  When your customers get what they want, when they want it, they become very satisfied customers.  That is the value of a lean competitive advantage.

9. Eliminates your employee confusion

Simplified production planning, simplified purchase planning, and simplified work cells all lead to a simplified system.  Employees can see the simplification and easily understand the flow.  Confusion is virtually eliminated.

10. Minimizes your overproduction risks

Inventory can become obsolete quickly in today’s fast changing marketplace.  A lean kanban will reduce your exposure to excessive older inventory by focusing your production on customer demand instead of production planning.  If you only make what you need then there is little obsolete inventory risk.

Top Ten Reasons for Using a Lean Kanban

1. Visualizes your work
2. Reduces your Work In Progress (WIP)
3. Moves your work along Steadily
4. Releases your work on demand
5. Improves your work flow
6. Simplifies your production planning
7. Eases your purchase planning
8. Increases your customer satisfaction
9. Eliminates your employee confusion
10. Minimizes your overproduction risks

We have heard from several customers about the need for implementing ISO in their unique organizational settings.  Based on this feedback, we are currently developing an ISO QMS implementation guide with tools applicable in different business settings, including service organizations. It will augment our existing ISO 9001 QMS Procedures Manual, and will help answer questions like  ‘How do I get started?’ and ‘How do I roll out ISO in my company?’

As a publisher and professional services firm (not a manufacturer), we have seen benefits from implementing quality methods. We have clear metrics that we measure regularly and are always looking to improve our measurements or come up with better metrics. It is our belief that an implementation guide will provide practical implementation steps to organizations that want to work on their own with little or no help from consultants.

The initial release of the implementation guide, scheduled to be released in the first quarter of 2010, will include the planning, design and implementation tools we have used for our clients–and for ourselves–to become ISO-certified. We are also adding some additional tools and explanatory materials prepared specially for the implementation kit. The tool sets incorporate knowledge amassed over almost ten years of research, use, deployment at client sites, and publication of quality policies and procedures. Check out our recent article & blog series on process maps and current series on project management for more insights into what will be included in the implementation kit.

More companies will benefit from continuous improvement

ISO has helped Bizmanualz cultivate the belief and practice of continuous improvement. By using the “Plan – Do – Check – Act” methods on which most quality systems are built, we have focused on improving underlying processes and avoiding problems in the future. Our process orientation reinforces teamwork: we’re all in this together to improve the process that will create ever-better, sustainable results not only for our customers. By releasing the tools that we ourselves use  internally and for clients, we aim to help other organizations implement quality systems with equal structural support.

The ISO implementation kit will be as easy-to-use and self-explanatory as possible. To support this goal, we are developing a test program in which we will work with selected companies to test and use our implementation kit. If your organization has immediate plans to implement or improve its ISO or related quality system, please contact us through the Bizmanualz website or by commenting below this post. We will provide the implementation product at no charge for test customers in exchange for regular phone reports and occasional access to your facility so that we can learn from your use of the product.

For now I can recommend our ISO 9001 QMS Manual. While it is written from a manufacturing perspective, the principles, as well as many of the specific policies, procedures and forms, can be generalized for a service business. And it has been recently updated to conform with the ISO 9001:2008 standard.

Are you implementing a quality program at your organization? What will be your first step? How will you get started? What do you think should be in our implementation guide? Would you like to try the guide and let us know how to make it better? Leave a comment below or contact me directly at  dan@bizmanualz.com .

The swim lane and document maps that we blogged about recently are useful for describing processes.  The swim lane map showed us who was responsible for what: Dad was driving, Mom was navigating, and in this scenario our kids were the customers.

Information flow was better captured in the document map.  It identified the documents handed off at each step of the process.  It also showed when status or other information was not in document form, but was spoken.

Swim lane maps and document maps are descriptive rather than prescriptive: we use them to communicate what is happening today, not what we’d like to happen or what should be taking place.  To change the existing process, we need to map the activities at each step and critique them for the value they add to the process.  One way we can do this is with an activity map.

When It Comes to Making Changes, Start with the Small Things

Activity maps and “value stream” maps help us capture what is happening in the workplace (or, in my example, the family minivan).  Activity maps are great for identifying areas ripe for streamlining or eliminating — if the activity/process doesn’t add value, it probably doesn’t belong.

Using my family vacation example, I could call a family meeting, tape our swim lane and document maps to the dining room wall, and engage my wife and kids in a conversation about the process of driving to summer camp.  I would ask them for their opinions and insights about each process step, to identify opportunities for improvement.  (How popular this would make me!)  

We dig past generalities down to the tasks that we each perform.  We look at each task and determine what’s not necessary – see if we can skip or eliminate steps.  Would we get there faster?  Would we each let go of “non-value-added” activities?  I don’t know, but I know that an activity map could help us get the issues onto the dining room table. (Selling our analysis, conclusions, and the resulting change might require a rendered map, which I’ll cover in upcoming articles and blog posts.)

Here’s the driving process presented in an activity map:

The first row is the process step as appears in the swim lane and document maps for the “Driving” process. Second row is a tally of activities per step and the number of lean value-added steps. Next row is color-coded by responsible party. Green activities are value-added. Red represents waiting or other waste. All other activities (in white) should be reviewed for their necessity and potential improvement.

Green steps transform the product (travel) that the customer (passenger) is receiving. These steps add real or perceived value to the product, in the customer’s eyes, so they’re called “value-added” steps.  The green steps help transform the end product, whether or not the customer is aware of the transformation. 

The “check/fix car” activity (at the top of the “Drive” column) is an example.  Preventive maintenance in advance of the trip assures my customers a trouble-free trip, though they may not be informed of the oil change, tire rotation, fluid check, etc.  Other green steps – loading/unloading luggage, occasional status reports, driving — are readily apparent to my customers.

Few would argue that waiting doesn’t add value.  Any waiting “activity” (shaded in red) is a non-value-added step.  Today — “Star Trek” notwithstanding — it is impossible to arrive instantly at a destination.  Ideally, we would look to cutting “wait time”, but in our scenario it’s unavoidable.  (Dad could go faster, but the minivan and the law enforcement authorities have their limits.)  We note that some wait time is unavoidable in this case, and we proceed with the analysis.

The remaining activities (in white) will lead to further discussion and analysis.  We acknowledge that these individual activities are not what the customers are buying — they’re buying the whole experience.  But we can’t call all of them waste — some of them are necessary.

Can We Cut Activities?

In hindsight, the activity “Plan alternate route in case of trouble” could be considered waste.  We don’t know that we will run into slowdowns, detours, open drawbridges, or inaccuracies on the roadmap/TripTik.  You could cut that activity.

But we ran into all those problems.  Good thing we didn’t cut the activity. However, the activity is not value-added to my customers.  I could tout my wife’s exceptional planning skills and convert a non-value-added activity to a value-added one, in my customer’s opinion.  If road delays were rare or unlikely, I might argue for cutting that activity.  Either way, the Activity Map is the tool that helps make the conversation meaningful.

I thought a local route near Saugatuck, MI, would save us few miles and some time. I learned that you can’t always get there from here in coastal Michigan. Good thing that my navigator had a backup plan.