Redesigning a process you have not measured is decorating a room you have not seen.
The Real Process Is Not the SOP
The documented process is how work was meant to flow years ago. The real one has workarounds, side spreadsheets and heroics. Mine the system logs where they exist, and follow the work where they do not. The gap between the two is usually where the money is.
Find Where the Volume Actually Goes
Most processes concentrate: a few paths carry most of the volume and most of the cost. Quantify each path, items, minutes, money, and the redesign stops being a debate. The data picks the battles.
Redesign the Few Paths That Matter
Fix the top three paths, leave the long tail alone, and re-measure against the baseline.
- Mine or observe first. Never trust the SOP alone.
- Put a number on every major path.
- Redesign the top paths only. The tail is not worth it yet.
- Re-measure after, against the same baseline.
Measurement before redesign is slower by a week and faster by a quarter.
One week, one number