Process Map

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Process Mapping
Clara Moreno ASQ Section 1506 January 16, 2003
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Agenda

• 1. Definition
• 2. Elements
• 3. Steps
• 4. Examples
• 5. Workshop

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Process Mapping

• Identifies the sequence of activities or the
  flow of materials and information in a process
• Uses the techniques of flowcharting to
  understand a process
• Promotes team work
• Is a valuable tool for process improvement
• Is a visual living document used to monitor and
  update changes in the process.

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Elements

• A Process Map should include
• Process Boundaries
• Process Owner, Customers and Suppliers
• Sub-Processes
• Inputs/Outputs
• Data Collection Points
• VA/NVA Activities
• Cycle Time

Document a process as is not as should be
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Process Mapping Steps
1
2
3
Identify All Process Steps
Identify VA NVA Steps
Define Process Scope
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Review Process Map
List Process Inputs Outputs
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5
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Measure Process
Improve Process
Classify Inputs (Xs)
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Step 1

• 1. Define Process Scope
• Goals and Objectives
• Define process boundaries (start to finish)
• State the problem
• Set process metrics
• Flow time, rework, travel distance,
  defects/errors
• Establish key requirements
• Transactional or Production process

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Step 2

• 2. Identify all process steps
• Observe process (attach yourself to the flowing
  part)
• Collect Data (list process as a verb followed by
  a noun, record time, distance traveled, etc)
• Document your observations

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Step 2 Cont.

• 2. Identify all process steps
• Write information on Postit Notes. Example
• Align all the steps horizontally on a wall or
  board
• List the parameters that can change a product
  characteristic at that step (machine settings,
  supplies)

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Step 3

• 3. Identify VA and NVA steps
• Value Adding (VA) steps have the following
  characteristics
• Something the customer would be willing to pay
  for
• Transforms the product or service (shape, smell,
  color)
• Is done right the first time!
• Non Value-Added (NVA) steps are classified as
• NVA Necessary (fill out paper work)
• NVA Unnecessary (waste) (rework, delays, idle)

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Step 4

• 4. List Process Inputs and Outputs
• Inputs all necessary parameters to complete a
  step
• 6Ms Man, Machine, Measurement, Method, Material
  and Mother Nature
• Outputs end-product parameters that are
  measurable or assessable
• Inputs outputs can be identified by
• - Brainstorming - Work instructions
• - Operators experience - Industry standards
• - Engineering knowledge - Scientific theory

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Step 5

• Classify Process Parameters (Inputs)
• Classify inputs into the following categories
• N Noise Factors - Uncontrollable factors in
  the process
• C Controllable Factors - Process factors that
  can be changed to see the effect on product
  characteristics.
• S Standard Operating Procedures - A procedure
  is used to define and run those factors.
• Cr Critical Factors Important factors that
  determines the outcome

Process Parameters
Product Parameters
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Step 6

• 6. Measure The Process
• Show total time as VA and NVA percentages for the
  entire process
• Analyze the NVA steps, measure distance traveled
  (feet) and investigate time wasted. (time
  operator goes away from the working area, waiting
  and idle time)

Savings Target
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Step 6 Cont.

• 6. Measure The Process
• Calculate Plant Rate (Takt time) rate for
  producing a product, and its components, based on
  customers demand.
• Plant Rate Operating available time per shift
  
• Customer demand per shift
• available time per shift (lunch breaks)
• (8hr/shift) ? 480 min 60 min 420 min
• Example
• Plant Rate 420 minutes 70 minutes/part
• 6 parts

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Step 6 Cont.

• 6. Measure The Process
• Calculate Cycle Time total time elapsed to run
  all the steps in a process to complete a part and
  start the next one.

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Step 6 Cont.

• 6. Measure The Process
• Calculate Flow Time total scheduled time to
  complete a part

Produces more parts in less time!
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Step 7

• 7. Improve The Process
• Concentrate to eliminate waste
• Unnecessary motions, steps
• High volume of inventory, overstock
• Overproduction
• Transporting
• Waiting, idle, queuing
• Defects, scrap
• Under-utilization of resources (people,
  equipment)
• Target the NVA steps as process improvements

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Example 1 Inputs Outputs
Process Parameters
Product Parameters
Taken from ASQ example
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Example 2 Transactions
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Example 3 Process/Product Benchmarking
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Example 4 - Process Map Simulation

• Process Maps can be simulated (iGrafx)
• Is a predicting tool on how the process behaves
  under different conditions
• Once you have mapped the process you can simulate
  it to observe the effect of changes without
  actually implementing them

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Summary

• Process Mapping will help identify
• All process steps (value-added non value-added)
• Waste in the process
• Input parameters (Xs)
• End product parameters (outputs) (Ys)
• Characterization of all parameters
• Data collection points
• New process improvement projects
• Sources of variation

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Summary Cont.

• Process Mapping is used to
• Understand process flow
• Find where/what/when/who/how waste is being
  created
• Define elements of cycle time
• Eliminate or combine steps
• Improve process flow
• Re-layout the process
• Reduce variation, cycle times, rework, waste and
  manpower
• Allocate resources better

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Workshop

• You have been assigned to a team to do a process
  map on how to Make a Copy. Please do the
  following steps
• List all process steps
• Construct a process map
• Identify Inputs and Outputs for each step

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Solution
Place Documentin Copier
Set Number of copies
Enter size desired
Set brightness
Press Start button
Finish

• Size
• Size Button

• Darkness
• Dark button

• Copies Req.
• Number button

• Hinges
• Glass clean

Correct Size selected
Correct number of copies

• Document set right
• Glass clean

Correct copy

• Right darkness