A process is defined as a sequence of stages used to accomplish a certain goal. Once a process has been defined, it is preferred that certain activities or stages be carried out to guarantee a repeatable result, irrespective of who or when the actions are completed. We won't be able to get the same outcomes if we don't understand the way something was done. This level of consistency is crucial in commercial operations involving clients and products.

What is Process Variation ?

Process variation is a concept of importance in business improvement methodologies such as the Six Sigma method. Defined as the numerical value used to describe the degree of individual variation within a group. Process variation occurs when manufacturing procedures deviate from a predetermined pattern.

This is one of the main reasons for quality problems in transactional and manufacturing operations. Problems with product quality are frequently not discovered until they have developed into major accidents. Now that the issue has been located, management must take the necessary actions to stop it from happening again.

Types of Process variation

There are primarily two categories of process variations:

1. Common Cause Variation

A common cause variation, is the outcome of factors that are either known or unknown. This variance's causes are often measurable and inherent to the system. 99% of values are predicted to be found within three standard deviations of the mean, which is where common cause variations often occur. If you are projecting on a control chart, a few irregular spots that fall under the control limit will show this variance.

A statistically consistent process results from the influence that common cause variation exerts on the process outputs being predictable and controlled. You will need to adjust something fundamentally if you want to get rid of this common cause variation.

2. Special Cause Variation

Unexpected events that impact a process are referred to as special cause variation. These changes are rare, weren't seen, and can't be measured. These random causes are the outcome of a system modification that caused a problem.

The introduction of specific cause variation might make things more difficult since they happen unexpectedly. Modifying the procedures, materials, or methods will resolve this issue.

Examples of Process Variation

A packaging station with a chain that speeds up and slows down the movement of products on the conveyor belt while remaining within control limits is an example of a common cause variation in a process.
In a manufacturing setting, special cause variation can be caused by environment, materials, labor, technology, equipment, and a variety of other factors.

Assuming the conveyor's motor fails and causes a sudden increase or decrease in speed, the production process would be out of control and become a special cause variation.

Another example would be when a new person is hired and starts working immediately without any training. There is no prior understanding of the process leading to outputs that are far from control limits.

Tracing a quality issue to its source will be much easier if roles are clearly assigned, standards are developed, and workflows are carefully monitored.

The Benefit of Understanding Process Variation

Process variation can assist prioritization of tasks and encourage long term sustainability. Financial performance, operations expenses, and customer happiness may all be improved by identifying, defining, measuring, and minimizing variance. With the understanding that reducing variation would increase overall performance, we should be vigilantly looking for causes of variation and actively attempting to decrease it.

Expect to have some process variation

Some process variation should be anticipated unless you are operating in a highly controlled setting where external variables have limited influence.

Imagine that despite your agreement to deliver packages in 12 hours to your client, your vehicle breaks down. Or else, if your delivering through a courier service and it had some sort of issue. You're still doing well if you have a backup plan in place and your customer eventually receives their delivery within the expected period.

it is unavoidable for production processes to vary to some extent. Whether the inputs that create the fluctuation are predictable and under control is the main issue.

You can manage the problem if you comprehend this variation, can take it into account in the result, or can find a workaround. However, having a broad understanding of the kinds of process variation may establish a solid basis for optimization.

7 ways to manage process variations effectively

Companies can manage their requirement for changes beyond their main procedures effectively. The following are seven ways to remember:

1. Establish a global standard protocol that will serve as the basis for all variations. You can apply global processes as standards against which any variations can be examined.

2. Ensure that teams can easily access the appropriate variations. Take advantage of a system that guides teams to the process variations that are relevant to their business unit, area, or other aspect. As an alternative, provide a data base from which they may select the applicable variations.

3. Integrate global reporting. Administrators of a global process can assess modifications and subsequently reject or approve them.

4. Where applicable, establish local distinctions. Experts can design local process variations, yet they must ensure that these variations are distinguished from the standard processes.

5. Check that any process changes are clear. Every variation of every procedure needs to be thoroughly examined and evaluated against industry standards.

6. Compile and examine time and cost information. With this knowledge, you can assess the efficiency of process variations by contrasting their efficacy against the standard procedures.

7. Inform operators of process variations or any adjustments to the established procedures. They can examine the modifications and either add them to their unique variations or discard them.

Performance Solutions

Our Performance Improvement Strategy outlines key Quality Management System concepts and accelerates implementation with focused targeting, delivering a quick solution to specific challenges, for businesses that require smooth operational transition and a successful process change. Some cases would include:



• Focusing on the lean Six Sigma methodology 6 M's aspects that contribute to process variation, to develop operating guidelines and instruct staff how to properly execute a process.

• Putting in place an operations management system to ensure the leader's regular work involves monitoring, to evaluate and maintain improvements made by standardizing operational processes.

If you're prepared to place your Improvement efforts on limiting special cause variations and ideally control common cause variations to build more stable, consistent processes, BPRIGHT can help! Contact us today.

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