How do you test and evaluate the effectiveness of your backup plans using PFDs?

1 Identify the risks and backup plans

The first step is to identify the possible risks and uncertainties that could affect your process, and the corresponding backup plans that you have or need to develop. Risks could be internal or external, such as equipment failure, human error, supply chain disruption, natural disaster, or regulatory change. Backup plans could be alternative sources, methods, routes, or resources that you can use in case of a risk event. For example, if your process relies on a certain supplier, you might have a backup plan to use another supplier or a different material.

2 Create the normal PFD

The next step is to create a PFD that shows your normal process, without any backup plans. You can use symbols, labels, arrows, and colors to represent the different elements and flows of the process. You should also include relevant data and metrics, such as time, cost, quality, quantity, or efficiency, to measure the performance and outcomes of the process. For example, if your process is to produce a product, you might show the inputs, outputs, and steps involved, as well as the production rate, cost per unit, and quality standards.

3 Create the backup PFDs

The third step is to create one or more PFDs that show your backup plans, depending on how many risk scenarios you want to test. You can use the same format and symbols as the normal PFD, but highlight or annotate the changes or deviations that occur when you activate a backup plan. You should also update the data and metrics to reflect the impact of the backup plan on the performance and outcomes of the process. For example, if your backup plan is to use a different supplier or material, you might show how that affects the input availability, cost, quality, or quantity.

4 Compare and evaluate the PFDs

The final step is to compare and evaluate the normal PFD and the backup PFDs, and see how they differ and how they affect the overall process. You can use criteria such as feasibility, reliability, efficiency, effectiveness, or resilience to assess the strengths and weaknesses of each backup plan. You can also use tools such as sensitivity analysis, scenario analysis, or simulation to quantify and visualize the impact of different backup plans on the process. For example, you might compare how each backup plan changes the production rate, cost per unit, quality standards, or customer satisfaction.

By using PFDs, you can test and evaluate the effectiveness of your backup plans in a systematic and visual way. You can also identify areas for improvement or optimization, and ensure that your backup plans are aligned with your process goals and objectives.

5 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?