Suyash Ketankumar Wani

ECRS method for Process Improvement
ECRS stands for Eliminate, Combine, Rearrange, and Simplify. This is a Lean technique used for removing wasteful steps in manufacturing processes or even office procedures. This can be better put together with a value stream map as well to identify necessary and complex steps within production lines. While first implementing ECRS, complex and time-consuming tasks are reviewed with the goal of successfully applying any one or all of the ECRS Strategies acronym. The end result is always aimed to streamline any process for workers and create a more efficient business as a whole. The four methods are:
Eliminate – Identify the steps in a process that can be eliminated without decreasing production value. Ask questions such as: Can we eliminate the root cause? What is the problem with this situation currently? Do we need a new process? Combine – If nothing can be eliminated, see if any steps can be combined. Ask questions such as: Can the same person do both steps? Can we merge this step with another? Rearrange – Rearranging steps may help in making the process work faster, easier, or safer. Ask questions such as: Is this the best sequence of progression? Can we rearrange the process steps, process flow, or training? Simplify – Simplifying steps can make complicated tasks much easier to understand. For example, by providing visual aid or better equipment, process can be simplified. Simplifying a process helps in improving completion times and improve accuracy. Ask questions such as: Why do we need this detail? What is the objective of the process? How do others do it? The ECRS Lean technique helps in faster implementing application of new ideas after conducting brainstorming meetings for potential improvement opportunities with those who perform the task. This happens most of the time, newly designed or newly processes set don’t require money to be spent, it just requires restructuring and making improvements upon old procedures. The major advantage of ECRS is implementation, if something is not working in a planned manner it can be changed without overspending of money and resources on an unproven solution.
When to use ECRS Technique
o    When we need Immediate Improvements
o    To produce quick practical ideas to make the process lean
Variations
o    Supports PDCA (Plan-Do-Check-Act)
o    Can be done in templated form way, combining with 5W, 1H
o    Easiest way for Process Map Analysis
 
 
 
 
 
 
 
How to do ECRS
·         Do it with the "doers" , it’s a lean technique
·         Draw the process map and write the every process steps
·         the steps should be mentioned in detail till the end - lower level ( should be "go to the printer" "get print out" and NOT just print)
·         Write any known information/data on the process steps Example,
o    no of errors
o    Amount of time to the activity
o    Show hand offs
o    Elapsed time : Difference between the amount of time elapsed between hand over and take over
o    mark rework loops
o    An optional or Alternate step should also be mentioned
After the above steps, we should start asking questions
·         Eliminate - what if we don't do this step in an intended manner, does this step add any value . Example, instead of mentioning the printing and scanning step, can we directly turn it to PDF 
·         Combine - which steps can be combined to be identified
·         Rearrange – which way the work to be performed in the best sequence
·         Simplify - why do we need this detail, is this best way to do it Example, can we create a macro , a calculator , can we automate this
·         Once we are done with the above exercise mentioned – we should go out on the floor and start implementing it