Process Mapping

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 Document a process
“as is” not
 Data Collection Points “as should be”
 VA/NVA Activities
 Cycle Time

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 Process Mapping Steps
1 2 3
Define Identify All Identify VA &
Process Process Steps NVA Steps
Scope

4
Review List Process
Process Inputs
Map & Outputs

7 6 5
Improve Measure Classify
Process Process Inputs
(X’s)

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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
Delay/Wait
Transport
Process

Inspect

Rework

Step "As Is"

Store

Time Distance Quantity VA NVA Comments

# Process Steps

1 R
2 R
3 R
4 R
5 R

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 Step 2 – Cont.
2. Identify all process steps
 Write information on Postit Notes . Example: ®

Step Part
# #
Process
Name
Set up Run
time Time

 Align all the steps horizontally on a wall or board

Step Step Step
Start Finish
1 2 3

 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
Input Process Output
X’s Y’s
 Inputs: all necessary parameters to complete a step
• 6M’s: 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
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

Input Process Output

X’s Y’s
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
VA
16%

Savings Target $$

NVA
84%

 Analyze the NVA steps, measure distance traveled (feet)

and investigate time wasted. (time operator goes away C. Moreno.12
Identify opportunities for quality, cost and schedule improvements
from the working area, waiting and idle time)
01/16/03 Process Mapping.ppt
 Step 6 – Cont.
6. Measure The Process
 Calculate Plant Rate (Takt time)– rate for producing a
product, and its components, based on customer’s
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.

Step Step Step Step Step Step

Start Finish Part 1 Start Finish Part 2
1 2 3 1 2 3

Cycle time = 70 min Cycle time = 70 min

Flow time = 140 min

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 Step 6 – Cont.
6. Measure The Process
 Calculate Flow Time – total scheduled time to complete
a part

Step Step Step

Start Finish Part 1
1 2 3

Step Step Step

Start Finish Part 2
1 2 3

Flow time = 93 min

Produces more parts in less time!

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 Step 7
7. Improve The Process
1. 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)

2. Target the NVA steps as process improvements

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 Example 1 – Inputs & Outputs
Step 1 Step 5
Step 2 Step
Begin Time Logon to Step 3 Save and End Time
Goto 4 Check
Entry Initial Enter Data Release Entry
Timesheet Data
Screen Data

Employee/ C Data Entry Profile N Mouse CrC Entry Period CrC Verify N File Menu
Operator C Personnel # N GUI Toolbar P New Charge P Corrections N GUI Toolbar
Worked Hours CrC Logon Passwrd N File Menu P Absence CrP Hours C Operator
Time Entry Process

Network CrC Logon ID C Operator P Change CrP Charge # CrN Software

Computer C Operator CrN Software P Delete N Software
Software N Software C Operator

Process Parameters
Hours Recorded
Employee Data Entry Screen Accurate Hours Transaction Saved
< 8 Hours
Verification Timesheet Area Correct Charge # Hours Recorded
>8 Hours
Worklist Area Hours Released
Charge # Assigned
Time Period
Legend Absence/Atten. Code
C Controllable
Cr Critical
N Noise
P Procedure Product Parameters
x Input
Taken from ASQ example

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 Example 2 – Transactions
Manufacturing
No
Rework
Start 1 2 Is it ood? Finish
Authorization

15
incomplete Yes
drawings Copy
Copy #1
Doc #4

15 min

Solution A
Miami

Research
Solution B
problem
2 days

2 days

Send paperw
Solution C
ork to HR

No

Make 4 copies Yes

HR

Receive 2 Approve Copies are

& tracks Red Copy #2
signed copies red lines? distributed
lines

1 day 3 days 0.5 days

Quality

Rework
SSigned Copy Paperwork
Copy #3
#1

1 hr
Methods

Signed Copy Revise

Copy #4
#2 paperwork Release

Original
Marketing
Atlanta

Implement
Original Sign original
changes
2 days
10 to 12 mo

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 Example 3 – Process/Product Benchmarking

2M 3M 4M 5M 6M 7M
Atlanta Start 1

PAINT

6P
2P 3P 4P 5P 7P
Start 1
. )
Miamiu

PAINT

4S
1S 5S 6S 7S 8S
Start 2St 3S Obtain
St. l .
approval
Augustine

PAINT CURE

California Start 1 2 3 4 5 6
E1-0812

PAINT

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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 (X’s)
 End product parameters (outputs) (Y’s)
 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:
1. List all process steps
2. Construct a process map
3. Identify Inputs and Outputs for each step

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 Solution

Place Set Press

Enter size Set Finish
Document Number of Start
desired brightness
in Copier copies button

•Copies Req. •Size •Darkness

•Hinges
•Number button •Size Button •Dark button
•Glass clean

•Document set right Correct number Correct

•Glass clean of copies Size selected • Right darkness Correct copy

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