Table of Contents
             Process Improvement Cycle
                                                                     Benefits of Lean Manufacturing
             Process Improvement Benefits
                                                                     5-S Analysis
             Business Process Mapping
                                                                     Kaizen for Continuous 
             Process Improvement Roadmap
                                          Benefits of Six Sigma      Improvement
             Areas of Improvement
                                          Gap Analysis Chart         Kaizen Implementation
             Root Cause Analysis (Fishbone)
                                          Gap Analysis Matrix        Business Process Redesign Cycle
             Root Cause Analysts (5-Why)
                                          BPI Complexity &           Business Process Redesign 
             Deming Cycle (PDCA)
                                          Uncertainty                Strategies
             Six Sigma Analysis (DMAIC)
                                          Building Dynamic Range     Implementation Process
             Six Sigma Analysis (DMADV)
                                          Strategy Alignment         Implementation Gantt chart
             Benefits of Six Sigma
                                          Risk Identification        Improvement Timeline
                                          Risk Management Plan       Ongoing Monitoring & Reflection
                                          Run Charts
                                          Pareto Chart
                                          Lean Manufacturing Process
                                                          Process Improvement Cycle
                                                 Business process improvement (BPI) is a management exercise in which enterprise leaders use 
                                                  various methodologies to analyze their procedures to identify areas where they can improve 
                                                     accuracy, effectiveness and/or efficiency and then redesign those processes to realize 
                                                                                       the improvements.
                                          Identify                                                                         Redesig
                                                                                                                           n
                                0         Whether it’s a process that is underperforming or                     0          Reengineer the whole process from 
                                          important to a new strategy, identify & name it.                                 start to end increasing efficiency 
                                1                                                                               4          altogether.
                                          Mapping                                                                          Implementatio
                                                                                                                           n
                               0          Gather all information from start to end; steps,                      0          Implement improvement on a smaller scale to 
                                          requirements, inputs, outputs, time duration etc.                                check it’s efficiency comparing to previous.
                               2                                                                                5
                                          Analyze                                                                          Monitor
                               0          Analyze the gathered data and identify the                            0          Monitor result before standardizing the 
                                          bottlenecks & inefficiencies of the process.                                     process and before implementation on a 
                               3                                                                                6          larger scale.
                                               Process Improvement Benefits
                                            Better quality                 Improved business                  Reduced cycle 
                                            management                         efficiency                          time
                             Better cost                 Improved visibility of              More regulated                  Effective resource 
                            management                   process performance                 and compliant                     management
                    Business Process 
                    Mapping
                                        Bring together the                          Optimize the                      Analyze & identify areas 
                                           project team                            process steps                         for improvement
                   Identify the process                         Brainstorm                         Produce the baseline                     Implement & monitor 
                     we need to map                             the process                       business process map                         improvements
                                                                   steps
                                                02                                      04                                       06
                           01                                       03                                      05                                       07
                                                             Process Improvement Roadmap
                            Improvement                 Where we                   Goal in                   Goal in                  Goal in                  Goal in 
                                                                                                                                                                                     Measurables
                                  Goals                   are now                 6 months                 12 months                18 months                24 months
                                Spoilage              Spoilage rate is               Defect                 Breakdown               Spoilage rate            Spoilage rate 
                                                                                                                                                                                      Spoilage Rate
                               Reduction               too high (>8%)              awareness            analysis system in          less than 5%             less than 3%
                                                                                 program to all                place
                                                                                 Current audit 
                             Internal Audit           Internal audit is                                   Audit system               Audit Score              Audit score 
                                                                              practices reviewed                                                                                       Audit Score
                              Development               not effective                                       covers all               above 80%                above 90%
                                                                                 and improved
                                                           enough                                        functional areas
                                                       Poor workplace 
                                                                                 5S awareness            5S procedures &           5S audit score           5S audit score 
                                    5S                 organization &                                                                                                                 5S Audit Score
                                                                                 program to all         practices in place           above 75%                above 85%
                             Improvement                  conditions