What are some ways to observe and generate process design ideas?

one of the best methods that i have used during the years to understand AS-IS situation ,is answering to 5 questions to understand what is happening inside and outside the process 1-why 2-when 3-whom 4-where 5-what. after finding the answers of each question, it is more important how to prioritize answers ,delete unimportant issues or not related and then decide how to design new process as To-be situation . I really beleive that it is an art and very dependent to nature of designer . like what is happening in architecture.

When observing the current process, make sure to also register KPIs and measure them. These KPIs can later be measured again when the new process is in place to show what the improvements are.

Understand the current process and evaluate the positives and negatives of the current process. Keep thinking new and innovative solutions which can optimize or improve the existing process. Keep innovating!

And also when observe current process you should know what the goals of the current process, and you also know the target baseline of the current process, so if you know the baseline you can compare your process and other process with similar technology and process condition either good or need improvement.

Current process will act as your reference point if you are to come up with a Full Functional and Operating System (FOFs). Considering the current process will give you a baseline on the Input and Output with regards to Material Handling and Process Production Line. For Chemical Engineers or Process Control Engineers they even take into Consideration of the Mass and Energy Balance involved in your Process. You would even consider Physical Properties of the Materials being involved in the Process if you are dealing with Fluids say Viscosity & Flow rate. Another reference point would be collaborating with those who were involved in the current process offering and co-share Knowledge on what would be improved in the current process offering

One very important way to do this is by gaining experience from other fields. In sports this is called cross training. Often times this can generate new insights into good improvements that can be applied to your own processes. One famous example is Apple execs learning from a luxury hotel chain how they handled customer service. Lessons learned were then implemented in the first physical Apple store.

After you familiar and know the process, you task is to find the root cause first before generate idea, many methods can be used to find the root cause like why why analysis etc, you must find the real root cause of your problem so later you have a clear vision to generate ideas to tackle your problems..

It is also important to break & align your process into key steps & execution order… once you have clarity on the flow of activities, you evaluate if any of the problems identified during problem definition are already addressed by changed flow or if any new problem is anticipated with the changed flow of steps. Then start either putting ideas against each individual step.

After you find root cause and problem, probably you also have multiple ideas to solve it..but you should select the best suited ideas for your process, You can use best practice, economical approach or reliability approach, even you can make your own matrix to select best option among the ideas.

Ideas against each step can then be voted based on value it brings to current step as well as steps down the flow. For example, collecting certain metrics at a previous step may help evaluate efficiency of the process at a much later step, this infusing intelligence into the process.

Communication is something important, we run the plant with numerous people with different background like process engineer, operation engineer, production supervisor and field technician they must know and understand your ideas so the improvement can run sustainability. you might be a designer, but the people who operate the plant is not only you, others has to be involved so every section in plant has own role in this improvement and make an impact both on the plant operation and their knowledge you can communicate during tool box meeting, presentation and conduct training for team members, you might have feedback from others about your ideas so in the future you have a bright vision to select ideas etc.

The earlier you involve the users of the process in the improvement of it, the better the chances of success. People mostly want to feel heard, and often know which things work well and which don’t. If your audience doesn’t feel heard, they will be very unlikely to support the new process.