Chapter 4 Process Flowcharting / Process Mapping


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9/4/2012
Chapter 4 Process Flowcharting /
Process Mapping
Introduction
• A flowchart provides a picture of the steps that are needed to create a deliverable. • Maintain consistency of application • Identify opportunities for improvement • Identify key process input variables (KPIV) • Train new personnel • Describe activities during audits
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Introduction
• A flowchart provides a complete pictorial sequence of what happens from start to finish of a procedure. • Procedure documentation • Manufacturing processes • Work instructions • Product development steps
• It is better to create flowcharts after unsatisfactory baseline measurements of the overall process are identified. • Level of detail • How the flowcharting process be conducted
Introduction
• Flowcharting of key processes should lead to the establishment and documentation of a standard operating procedure (SOP).  reduce variability and cycle time.
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Introduction
• An alternative or supplement to a detailed process flowchart is a high-level process map that shows only a few major process steps as activity symbols.
• For each of these symbols key process input variables (KPIVs) to the activity are listed on one side of the symbol, while key process output variables (KPOVs) to the activity are listed on the other side of the symbol.
Introduction
• SIPOC (suppliers, inputs, process, outputs, and customers) is a high-level process map that adds supplier and customer to the IPO.
• SIPOC can be useful as a communication tool that helps team members view the project the same way and helps management know where the team is focusing its efforts.
• For each category of SIPOC the team creates a list.
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4.1 S4/IEE Application Examples: Flowchart
• An S4/IEE project was created to improve the 30,000-footlevel metric, for days sales outstanding (DSO). A process flowchart was created to describe the existing process.
• An S4/IEE project was created to improve the 30,000-footlevel metric for the diameter of a manufactured part. A process flowchart was created to describe the existing process.
4.2 Description
Standard symbols:
Terminal: Start / End Decision Symbol Activity Symbol Connector (On-page or off-page)
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Example: Process Flowchart

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www.breezetree.com/.../8D -process-flowchart.png
4.3 Defining a Process and Determining KPIVs / KPOVs
• Consider and describe the purpose and the process that is to be evaluated. • Reduction of cycle time • Reduction of defects • Improved consistency of operators • Reduction of new operator training time • Reduction of product variability • Reduction of hidden factory reworks
• Define all steps to create a product or service deliverable.
• Brainstorming session to list ideas for improvement • Value-add / no-value-add steps
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4.5 Focusing Efforts After Process Documentation
• To assess all process steps as value-add or no-value –add to the end result of the process.
• Items in a cause-and-effect diagram are assigned a classification of control or noise. SOP for the process are examined to minimize the impact of the identified causes.
• Use of activity-based costing (ABC) for process steps.
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Chapter 4 Process Flowcharting / Process Mapping