03-TT-Process-Mapping

16sGreenbeltTrainingProcessMapping2ProcessMappingWherearewe?•ProcessMappingallowsustovisualizetheprocess.•ItcanbeusedtoevaluatewasteintheprocessandidentifyKPOVs.MeasureImproveControlAnalyzeDetermineKeyProcessOutputVariables(KPOV)ValidateMeasurementsystemforKPOV’sAnalyzePatternsinDataEstablishProcessCapabilityforKPOV’s3ProcessMappingApplicationExamples:•Manufacturing:Ateamisevaluatingscrapgettingtothecustomer.Aprocessmapiscreatedtodeterminewherethedefectscouldbeaccidentallyenteringtheprocess.•Manufacturing:Anewteamisformedandnotallteammembersarefamiliarwiththeprocess.Aprocessmapiscreatedtoeducatetheteam.•Administrative:Ateamisevaluatingtheresponsetimetoahelpdeskcall.Aprocessmapiscreatedtounderstandthestepsandtimesforeachstep.4ProcessMappingLearningObjectives•LearnhowProcessMappingfitsinwithProcessImprovement•OverviewtheusesofaProcessMap•DifferencebetweenTopLevelMap&aDetailedMap•LearnhowtobuildaProcessMap,stepbystep•CompleteaProcessMappingExercise•ReviewexamplesofProcessMaps5ProcessMappingyfxxxk(,,...,)12ProcessMapping•ShouldDescribe:–Majoractivities/tasks–Sub-processes–ProcessBoundaries(toplevelvs.detail)–ProcessInputsX’s–ProcessoutputsY’s–ProcessstepoutputsY’s•Shouldbereviewedfrequentlyandupdated6ProcessMappingWhatIsAProcessMap?Processmapsneedtobemodifiedtofittheparticularneedsofanyspecificprocess.Agraphicalrepresentationofaprocessflowidentifyingthestepsoftheprocess,theX’sandY’softheprocessandopportunitiesforimprovement.TypicalOrderFulfillmentProcessCustomerPlacesOrderSendordertowarehouseforpickingIsordercorrect?NoYesCallCustomerandmakecorrections.IsProductAvailable?NoYesPickproductfororderDoesCustomerhaveothershipments?YesNoWillproductbeavailablebeforeorderships?YesPlaceorderonholduntilproductavailableCancelOrderNoIsproductionscheduledtomanufactureproduct?Canproductionmanufactureproductintimeforshipping?NoYesNoWillCustomeracceptbackorders?YesExpeditemanufacturingscheduleNoShipOrderYesWillCustomerallowconsolidatedshipments?YesNoConsolidateOrdersCustomerReceivesOrderOrderEntryWarehousingSalesManufacturingTransportation7ProcessMappingStartingattheTopKeybusinessactivitiescanbedefinedatdifferentlevelsoftheorganization:–Level1=highest-levelviewofworkintheorganization–Level2=workthatflowsacrossseveraldepartmentsorwithinanentiredepartmentorworkarea–Level3=adetailedviewofofaparticularprocessFillingSealingPackingNewProductdevelopmentDemandGenerationDemandFulfillmentCustomerServiceOrderingMaterialsProducingPickingShippingMixingLevel1Level2Level38ProcessMappingUsesoftheProcessMap1.Providesastep-by-steppictureofthe“as-is”situationfordiscussionand/orcommunication.2.Definesandhighlightsareasforimprovementinaprocess.Thesecaneitherbeeliminationofnon-valueaddedstepsoradditionofneededstepsdependingonthedesiredoutcomeoftheprocess.3.Documentshiddenfactory.4.AvenueforbrainstormingXsandYsinteam.Processmapscanbeusedonanytypeofprocess:manufacturing,design,service,oradministrative.9ProcessMappingStepstoCreateaProcessMap1.Defineproblemandscope.2.DevelopanUpperLevelProcessMap3.IdentifyProcessStepsWithintheBoundaries4.MapDataCollectionPoints5.ListOutputVariables(Y’s)foreachstep6.ListInputVariables(X’s)foreachstep7.CharacterizetheInputs8.Addthespecificationsandtolerances9.IdentifystepsasValueAddedorNon-ValueAdded10ProcessMappingTeamName:InvoicingImprovementInitiatorsProjectStartDate:January1,2003TeamMembers:BillBilling,FeliciaFinance,AxelAccounting,ReedReceivables,SidSystems,andSallySalesCustomers:Allexternalcustomers,FinanceDepartmentProblemStatement:Requisitionandreceivingprocesshasaveraged30daysforthepastyear.TeamObjectives:Reducerequisitionandreceivingprocessfrom30daysto5daysbyMarch30.Metrics:Timetoreceivingmaterials(fromrequisition)InputBoundary:CustomerrequestionOutputBoundary:CustomerreceivesproductExpectedCompletionDate:March31,2003ActualCompletionDate:Approvals:TeamLeader:GrantGreenbeltTeamChampion/Sponsor:CoryControllerStep1:ProblemStatement1.Defineproblemandscope.2.DevelopanUpperLevelProcessMap3.IdentifyProcessStepsWithintheBoundaries4.MapDataCollectionPoints5.ListOutputVariables(Y’s)foreachstep6.ListInputVariables(X’s)foreachstep7.CharacterizetheInputs8.Addthespecificationsandtolerances9.IdentifystepsasValueAddedorNon-ValueAddedYourproblemandscopeshouldcomefromyourTeamCharter11ProcessMapping1.Defineproblemandscope.2.DevelopanUpperLevelProcessMap3.IdentifyProcessStepsWithintheBoundaries4.MapDataCollectionPoints5.ListOutputVariables(Y’s)foreachstep6.ListInputVariables(X’s)foreachstep7.CharacterizetheInputs8.Addthespecificationsandtolerances9.IdentifystepsasValueAddedorNon-ValueAddedStep2:DevelopUpperLevelMapUseupperlevelmaptofurtherdefinescopeandassurescopeiscorrect.RequisitionofSuppliesIsrequisitionApproved?SuppliesareboughtanddistributedRequestisDeniedNOYES12ProcessMappingStep3:IdentifyProcessStepsWithintheBoundaries•Thispartoftheprocessshouldalwaysbecompletedasateam•UsePost-Itnotesforeasychangingofprocess•ProcessshouldshowtheCurrentStateoftheprocess,nothowitshouldrun•Interrogatetheprocessbywatchinginmanydifferentcondition