Flow Charts including Process Mapping

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Flow ChartsincludingProcess Mapping
CA/PA-RCA Basic Tool

• Sector Enterprise Quality Quality and Mission
  Assurance
• Northrop Grumman Corporation
• Integrated Systems

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What is a Process Flow Chart?

• 1. A Process Flowchart is a graphic
  representation of all the major steps of a
  process.
• It can help you
• a. Understand the complete process.
• b. Identify the critical stages of a process.
• c. Locate problem areas.
• d. Show relationships between different steps in
  a process.
• e. To identify and eliminate Waste

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Why use a Flow Chart?

• Process Flowcharts or Process Mapping helps you
  understand and improve a process by enabling you
  to
• Look for opportunities for improvement (gap
  between reality and ideal).
• Identify where defects are found (and where
  they are introduced).
• Identify where measurements need to be put in
  place.
• See where rework and bottlenecks occur.
• Elimination of Non Value Adding activities
  (Waste)

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Flowchart/Process Map levels
There are three major form of Process Map. These
are Macro High Level Overview Entire
Process Links with other Processes (the Big
Picture) Micro Operational Level Practical
Links between Inputs Outputs Operational
Measurements Controls Hyper-Micro
Design Level Details into Operator
Methods Material or Information
(Input) Specification
(Accuracy Precision)
System Functionality
Tip ! If in doubt about which Process Map to use,
start at the MACRO level.
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How to Use Flowcharts/Process Maps
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Considerations when Flowcharting/Process Mapping

• Remember S-I-P-O-C (Supplier-Inputs-Process-Outp
  uts- Customer). Start with C, then O, then S,
  then I, then P
• What level and details are required?
• What is a CTQs and non-CTQ-activity?
• What are the Measurable outputs?
• Know when to stop!
• Space, Time allowances (best time, day of the
  week to do it is ?)
• Group Dynamics Leader, Facilitator, Size of
  Group
• Using Post-It Notes / Wallpaper
• If available and appropriate, use Electronic
  versions ( use Aerospace-Industry standards)

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How do I do it?

• As a team, define
• process boundaries
• where does the process start
• what does the process include/non include
• where does the process end
• customer C.T.Q.s level of detail
• key process inputs (supplier) and outputs
  (customer requirements)
• identify and sequence process steps
• discuss and analyse the process
• agree next steps and next review.

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How do I do it? (contd)
Create a basic template of the process
1. Use sheets of flip-chart paper (or
wallpaper), 3 x 3 Post-It notes, and felt tip
pens. 2. Define the process or service to be
improved and write the name of the process on a
Post-It note. 3. Agree on the scope of the
process to be mapped, and mark process boundaries
with tape. 4. List suppliers,customers,
and inputs/outputs to/from the process. 5.
Define start and end process steps.
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How do I do it? (contd)
Brainstorm the steps in the process

• Tips
• At this stage
• Do not try to establish order
• Do not discuss process steps

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How do I do it? (contd)
Group into major process areas

• Tip
• decide on level of detail
• arrange Post-Its in sequence (horizontally,
  vertically)

• Tip
• Process steps should be Value-added i.e. answer
  yes to these questions
• Does the customer care ?
• Has something changed ?
• Has it been done right first time ?

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How do I do it? (contd)
Critically evaluate the Final Process Map

• Use map to identify where defects occur, where
  defects are introduced and where measurements
  need to be taken.
• Put attributes on each step - time, cost,
  value-added (from customer viewpoint).
• Use process map referenced to physical process
  layout (Spaghetti chart analysis).
• In complex maps, consider Output to Input
  mismatch.
• Be consistent with decision arrows (yes
  arrows in same direction).
• Challenge each process step and consider
  alternatives.
• Ask the WHY, WHAT, WHERE, HOW, WHEN, WHO - type
  of questions.

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Flow Charts
Questions?
Call or e-mail Bob Ollerton 310-332-1972/310-3
50-9121 robert.ollerton_at_ngc.com