Process Functional Modelling with PRIZ Platform

Why Traditional Process Improvement Isn’t Enough

Many organizations strive for efficiency, yet still find themselves bogged down by hidden complexities and invisible inefficiencies. Traditional process improvement methods typically target surface-level indicators like cycle time, defect rates, and direct costs. But what if the real opportunities for improvement are hidden deeper within your operations?

In our recent PRIZ Academy webinar, Alex and Anatoly Agulyansky revealed how Process Functional Modelling (PFM) provides a robust analytical framework that goes beyond superficial observations to uncover the real functional contributions of every operation within a process.

Understanding the Process Through PFM

At its core, a process is a structured system that transforms various forms of energy—materials, labor, information—into valuable products. Each process comprises multiple sequential operations, each performing a specific function. However, not all operations equally contribute value.

PFM classifies operations into four distinct categories:

1. Productive Operations: These create irreversible changes, adding direct value to the final product.
2. Providing Operations: These involve temporary actions that add no lasting value but increase cost and complexity.
3. Corrective Operations: These address errors or inefficiencies from earlier steps, often representing additional costs without substantial value.
4. Metrology Operations: These measurement activities gather information but add no direct value.

The Strategic Power of PFM

Analyzing processes through the lens of these four operation types highlights where true value lies—and where resources are wasted. PFM strategically guides teams toward:

• Prioritizing improvements in Productive operations.
• Eliminating or simplifying the provision of operations.
• Reducing or entirely avoiding Corrective operations by addressing root causes.
• Questioning the necessity of Metrology operations, removing them if they don’t clearly benefit decision-making.

Practical Applications and Real-World Results

The webinar illustrated how PFM has effectively identified hidden waste and complexity in sectors like semiconductor manufacturing, pharmaceuticals, and automotive production. By creating a detailed functional model of each operation, teams make informed, strategic decisions on process improvements, delivering measurable improvements in efficiency, yield, and profitability.

Leveraging PRIZ for Continuous Improvement

The PRIZ Engineering Thinking Platform was showcased as an essential tool that simplifies the application of PFM. PRIZ guides teams step-by-step in modeling their processes, classifying operations clearly, and fostering transparent decision-making.

Through PRIZ, organizations establish a common language around process improvement, empowering cross-functional collaboration and continuous improvement efforts.

A Shift in Process Thinking

Ultimately, PFM challenges traditional approaches by demanding a deeper understanding of processes. Instead of merely optimizing visible symptoms, PFM empowers teams to question and redefine the core structure of their operations.

If you’re ready to reveal hidden inefficiencies, simplify operations, and unlock significant performance gains, it’s time to embrace Process Functional Modelling with PRIZ.

Find the webinar deck here.