# Operations Management - Phase 2 Processes Backlog

## Overview

This backlog defines the key processes for the Operations Management specialization, organized into logical categories. Each process represents an automatable workflow that can be implemented using the Babysitter AI framework.

## Process Categories

### Category 1: Lean Operations

| ID | Process Name | Description | Complexity | Priority |
|----|--------------|-------------|------------|----------|
| LEAN-001 | Value Stream Mapping | Map current state material and information flows, identify waste and improvement opportunities, design future state value streams with implementation roadmap | High | P1 |
| LEAN-002 | 5S Implementation | Implement Sort, Set in Order, Shine, Standardize, Sustain workplace organization methodology with audit checklists and sustainability mechanisms | Medium | P1 |
| LEAN-003 | Kaizen Event Facilitation | Plan, execute, and follow up on rapid improvement workshops targeting specific process areas with measurable outcomes | Medium | P1 |
| LEAN-004 | Kanban System Design | Design and implement pull-based production control systems with visual management, WIP limits, and replenishment triggers | High | P2 |
| LEAN-005 | Standard Work Documentation | Document, implement, and maintain standardized work procedures with time observations, work sequence, and standard WIP | Medium | P2 |

### Category 2: Six Sigma and Statistical Process Control

| ID | Process Name | Description | Complexity | Priority |
|----|--------------|-------------|------------|----------|
| SIX-001 | DMAIC Project Execution | Execute Define-Measure-Analyze-Improve-Control methodology for process improvement projects with tollgate reviews and documentation | High | P1 |
| SIX-002 | Statistical Process Control Implementation | Implement control charts (X-bar R, I-MR, p-charts), establish control limits, monitor process stability, and respond to special cause variation | High | P1 |
| SIX-003 | Process Capability Analysis | Calculate and interpret Cp, Cpk, Pp, Ppk indices, assess process performance against specifications, recommend improvements | Medium | P2 |
| SIX-004 | Measurement System Analysis | Conduct Gage R&R studies, assess measurement system adequacy, identify and correct measurement variation sources | Medium | P2 |
| SIX-005 | Root Cause Analysis | Apply systematic problem-solving using 5 Whys, fishbone diagrams, fault tree analysis, and hypothesis testing to identify true root causes | Medium | P1 |

### Category 3: Theory of Constraints

| ID | Process Name | Description | Complexity | Priority |
|----|--------------|-------------|------------|----------|
| TOC-001 | Constraint Identification and Exploitation | Identify system bottlenecks, maximize constraint utilization, subordinate non-constraints, and implement five focusing steps | High | P1 |
| TOC-002 | Drum-Buffer-Rope Scheduling | Implement DBR production scheduling with constraint-based pacing, strategic buffer placement, and synchronized flow | High | P2 |
| TOC-003 | Throughput Accounting Analysis | Apply TOC financial metrics (Throughput, Inventory, Operating Expense) for decision-making and performance measurement | Medium | P2 |
| TOC-004 | Critical Chain Project Management | Apply TOC principles to project management with buffer management, resource leveling, and relay runner behavior | High | P3 |

### Category 4: Capacity Planning and Scheduling

| ID | Process Name | Description | Complexity | Priority |
|----|--------------|-------------|------------|----------|
| CAP-001 | Capacity Requirements Planning | Analyze capacity needs against demand forecasts, identify gaps, develop capacity strategies (lead, lag, match) | High | P1 |
| CAP-002 | Production Scheduling Optimization | Develop and optimize production schedules considering constraints, changeovers, due dates, and resource availability | High | P1 |
| CAP-003 | Sales and Operations Planning | Facilitate cross-functional S&OP process to balance demand and supply, align operational and financial plans | High | P2 |
| CAP-004 | Demand Forecasting and Analysis | Apply quantitative and qualitative forecasting methods, measure forecast accuracy, improve demand visibility | Medium | P2 |

### Category 5: Quality Management Systems

| ID | Process Name | Description | Complexity | Priority |
|----|--------------|-------------|------------|----------|
| QMS-001 | ISO 9001 Implementation | Implement ISO 9001:2015 Quality Management System requirements including documentation, processes, and internal audits | High | P1 |
| QMS-002 | TQM Program Development | Develop and deploy Total Quality Management program with customer focus, employee involvement, and continuous improvement culture | High | P2 |
| QMS-003 | Quality Audit Management | Plan, conduct, and follow up on internal quality audits with findings documentation and corrective action tracking | Medium | P1 |
| QMS-004 | Cost of Quality Analysis | Analyze prevention, appraisal, internal failure, and external failure costs to identify improvement opportunities | Medium | P2 |
| QMS-005 | FMEA Facilitation | Facilitate Failure Mode and Effects Analysis for products and processes, prioritize risks, implement controls | Medium | P1 |

### Category 6: Continuous Improvement Programs

| ID | Process Name | Description | Complexity | Priority |
|----|--------------|-------------|------------|----------|
| CI-001 | Operational Excellence Program Design | Design comprehensive operational excellence program with governance, methodology deployment, and capability building | High | P1 |
| CI-002 | A3 Problem Solving | Apply structured A3 thinking for problem-solving, project planning, and status reporting with coaching support | Medium | P2 |
| CI-003 | Benchmarking Program | Conduct internal and external benchmarking studies to identify best practices and performance gaps | Medium | P2 |

## Process Summary

| Category | Process Count | P1 Count | P2 Count | P3 Count |
|----------|--------------|----------|----------|----------|
| Lean Operations | 5 | 3 | 2 | 0 |
| Six Sigma and SPC | 5 | 3 | 2 | 0 |
| Theory of Constraints | 4 | 1 | 2 | 1 |
| Capacity Planning | 4 | 2 | 2 | 0 |
| Quality Management | 5 | 3 | 2 | 0 |
| Continuous Improvement | 3 | 1 | 2 | 0 |
| **Total** | **26** | **13** | **12** | **1** |

## Implementation Sequence

### Phase 2a - Foundation (P1 Processes)
1. LEAN-001: Value Stream Mapping
2. LEAN-002: 5S Implementation
3. LEAN-003: Kaizen Event Facilitation
4. SIX-001: DMAIC Project Execution
5. SIX-002: Statistical Process Control Implementation
6. SIX-005: Root Cause Analysis
7. TOC-001: Constraint Identification and Exploitation
8. CAP-001: Capacity Requirements Planning
9. CAP-002: Production Scheduling Optimization
10. QMS-001: ISO 9001 Implementation
11. QMS-003: Quality Audit Management
12. QMS-005: FMEA Facilitation
13. CI-001: Operational Excellence Program Design

### Phase 2b - Expansion (P2 Processes)
1. LEAN-004: Kanban System Design
2. LEAN-005: Standard Work Documentation
3. SIX-003: Process Capability Analysis
4. SIX-004: Measurement System Analysis
5. TOC-002: Drum-Buffer-Rope Scheduling
6. TOC-003: Throughput Accounting Analysis
7. CAP-003: Sales and Operations Planning
8. CAP-004: Demand Forecasting and Analysis
9. QMS-002: TQM Program Development
10. QMS-004: Cost of Quality Analysis
11. CI-002: A3 Problem Solving
12. CI-003: Benchmarking Program

### Phase 2c - Advanced (P3 Processes)
1. TOC-004: Critical Chain Project Management

## Process Dependencies

```
LEAN-001 (Value Stream Mapping)
    |
    +---> LEAN-003 (Kaizen Events)
    |         |
    |         +---> CI-002 (A3 Problem Solving)
    |
    +---> TOC-001 (Constraint Identification)
              |
              +---> TOC-002 (DBR Scheduling)
              |
              +---> CAP-002 (Production Scheduling)

QMS-001 (ISO 9001)
    |
    +---> QMS-003 (Quality Audits)
    |
    +---> QMS-005 (FMEA)
              |
              +---> SIX-005 (Root Cause Analysis)

SIX-001 (DMAIC)
    |
    +---> SIX-002 (SPC Implementation)
    |         |
    |         +---> SIX-003 (Process Capability)
    |         |
    |         +---> SIX-004 (MSA)
    |
    +---> SIX-005 (Root Cause Analysis)

CAP-001 (Capacity Planning)
    |
    +---> CAP-003 (S&OP)
    |         |
    |         +---> CAP-004 (Demand Forecasting)
    |
    +---> CAP-002 (Production Scheduling)
```

## Technical Requirements

### Data Integration
- ERP system connectivity (SAP, Oracle, Microsoft Dynamics)
- Manufacturing Execution System (MES) integration
- Quality Management System (QMS) data access
- Statistical analysis tool integration (Minitab, JMP)

### Process Inputs
- Process data and performance metrics
- Quality measurements and inspection data
- Production schedules and capacity data
- Customer requirements and specifications

### Process Outputs
- Value stream maps and improvement roadmaps
- Control charts and statistical analyses
- Capacity plans and production schedules
- Quality documentation and audit reports
- Continuous improvement project documentation

## Success Metrics

| Metric | Target | Measurement Frequency |
|--------|--------|----------------------|
| Process cycle time reduction | 20-50% | Per project |
| Defect rate reduction | 50% | Monthly |
| OEE improvement | 10-15% | Weekly |
| Inventory reduction | 25-40% | Monthly |
| On-time delivery improvement | 95%+ | Weekly |
| Cost of quality reduction | 20% | Quarterly |

## References

- Ohno, T. (1988). Toyota Production System
- Womack, J.P. & Jones, D.T. (2003). Lean Thinking
- Goldratt, E.M. & Cox, J. (2014). The Goal
- Montgomery, D.C. (2019). Introduction to Statistical Quality Control
- ISO 9001:2015 Quality Management Systems Requirements
- Pyzdek, T. & Keller, P. (2018). The Six Sigma Handbook

## Version History

| Version | Date | Author | Changes |
|---------|------|--------|---------|
| 1.0 | 2024-01-23 | Babysitter AI | Initial creation of processes backlog |

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*This backlog is part of the Babysitter AI Operations Management specialization framework.*
