By Thomas T. Fields, Jr.
A modular approach to process development can be used in conjunction with Six Sigma. This combined approach will enhance the finished process, reduce costs and improve the overall processes.
The Modular Approach
A modular approach is not new to design and construction projects. Modularizing construction components standardizes the sizes of finished projects, reduces the cost, increases quality and decreases installation time. Front-end design is simplified and development costs are likewise reduced. This modular approach has been expanded to include modular concepts of assemblies that again expedite the deployment of finished products, increased quality and reduced the cost of the finished facilities. Although the modular approach has been universally adopted for design and construction throughout the world, the approach has not been identified as a method for operating process development.
In the modular approach to process development canned sub-processes are developed that fit within large process development. A process for programming a digital subscriber line (DSL) should be the same as routing a programming request for digital television (DTV). Training the programmers is addressed when the overall process is in development. Why readdress the method of how an order is returned to dispatch and assignment due to facilities not being available? It should not matter if the order is a circuit, plain old telephone system or Ethernet – the process should be documented, available for all designers and used. The value of this approach is less development time/cost and a standardized method of implementation.
Individual modules should be well-documented and available for use by all process designers. While these modules are being developed it is important that they be reviewed in the context of operability, flexibility, cost and efficiency. Process designers should identify the inputs and outputs to the module, and review them periodically to ensure that operating system updates and changes to business rules are incorporated.
When a major process is under development a modular approach will enhance the finished process. It is important to note that the modular concept will only contribute to a total finished process design. Different products and technology will require additional elements to the process flow that are not used in other processes. The designer must be aware of when to develop new methods, and visualize if the new elements can be expanded for future projects and processes. If it can be expanded, the new element must be turned into a new module for future use.
Value of the Modular Approach
The real value of this concept lies in the ability to be forward looking and develop modules that address new developments in systems. Additionally, new system innovations can be identified and deployed prior to the beginning of a new project allowing the organization to be prepared for new process development and implement new processes with a minimum of work-arounds.
| Figure 1: The Modular Concept to Process Design |
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Six Sigma Integration
As someone once stated the difference between failure and success is doing things nearly right and doing things exactly right. Six Sigma facilitates itself to process development, either in a project mode or in an ongoing operational mode.
The define, measure, analyze, improve and control (DMAIC) phases fall in line with a modular approach to process development. Three scenarios exist for Six Sigma integration into modular process development:
- Individual module level: When a module is developed it must be broken into its most elemental parts. The module must be evaluated for cost, quality, field operability and integration into future processes. These modules must be reviewed periodically to ensure they are operating at their most efficient levels. Metrics must be developed at the module level to evaluate their effectiveness.
- Project level: This is identical to the module level except that not only are the pieces evaluated individually, but the entire process must then be re-evaluated as a whole to ensure that all the pieces work together as efficiently as possible. Again metrics must be developed to evaluate its effectiveness.
- Day-to-day method: Using DMAIC for day-to-day operations throughout the entire organization instead of just process development, is the most difficult to implement and requires a mindset change that permeates throughout an organization. This undertaking is massive in the operating strategy of a corporation, but the rewards are equally proportional to the implementation efforts. The key is dedication from the organization to deploy Six Sigma and develop a full-featured training program to change the mindset of the employees.
Conclusion
As stated by management expert Peter Drucker, "whenever you see a successful business, someone once made a courageous decision." A modular approach to process development allows an organization to look forward in developing processes, decrease deployment time, reduce development costs and increase process quality. Integrating Six Sigma into this concept further enhances the effectiveness of the modular approach. Deploying a modular approach and integrating Six Sigma offers opportunities for a total project managed approach to integration within an organization's structure.
Thomas Fields was born in Farmerville, La., graduated from Farmerville and following a tour of Viet Nam with the US Navy, attended and graduated from Northeast Louisiana University in construction management. Mr. Fields obtained a commission in the Army Reserve and was recruited by ARAMCO for a management-training program. He spent 17 years as a project engineer designing and constructing offshore and onshore pipelines, plants and facilities. Mr. Fields has also worked as a project manager for International Paper in Bastrop and is currently an operations manager for CenturyTel Communications, headquartered in Monroe, La. Contact Thomas T. Fields, Jr. at thomas.fields (at) centurytel.com or visit http://www.centurytel.com/.
