Question

In the context of resilient workflows, why must variance be managed at the source rather than through end-of-process inspection?

Accepted Answer

Managing variance at the source is essential for resilient workflows because it prevents defects from being created, whereas end-of-process inspection only identifies defects that have already occurred. Variance refers to any deviation from a defined, stable process that leads to inconsistent results. When variance is managed at the source, workers or systems use built-in controls to ensure each step is performed correctly as it happens. If you wait for end-of-process inspection, which is a final check after a product or task is completed, you incur the cost of wasted time, materials, and labor spent on a defective unit. Furthermore, inspection is reactive and prone to human error, meaning it may fail to catch every issue, whereas source control is proactive and ensures quality is built into the workflow itself. An example of source management is a mistake-proofing device that physically prevents a machine from operating if a part is misaligned, ensuring the error never happens. Relying on inspection would instead allow the machine to produce the misaligned part, requiring the process to stop later to discard or rework the item, which interrupts flow and weakens organizational resilience.

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In the context of resilient workflows, why must variance be managed at the source rather than through end-of-process inspection?