Goodrich
Continuous Improvement
GR - Process Mapping.ppt
Process Mapping
A HOUSE WITHOUT WASTE
CUSTOMER
ENTERPRISE EXCELLENCE
Leadership
Pull
DFM/A
DOE
% Load
Charts
MRS
Jidoka
SWS
SMED
Problem
Solving
TPL
Process
Mapping
Visual
Hanadashi
Controls
7 Principle Wastes
Supplier Cert.
Curtain
Operation
Adjustment
Elimination
5S
5 Whys
Mistake
Proofing
SWCS
Right
Sizing
MultiSkilled
Make It
Ugly
Physical
Layout
SWIP
6
SIGMA
Line
Stop
Time
Obsern
Creativity B 4 $
Time
VA - NVA -
Profitability
Employment
Stability
Flow
Linkage
Process
Mapping
Standard
Work
Voice of
the
Customer
Total Employee
Engagement
QFD
AQS
3P
Process Mapping
Learning Objectives
What is a Process Map?
When/Why use Process
Mapping?
How do you construct a
Process Map?
How does a Process Map
identify waste and make
improvements?
Process Mapping
Process Mapping
Process Mapping
Transportation
Inspection
Business Process
Machine part
Assemble parts
Pack
Heat treat
Repair part
Inspect part/assy
Check paperwork
Verify stamps
Check tooling
Process Mapping
Kaizens - Detail
Process Mapping
Purpose
Describe current process
(document reality)
NOT
Process Mapping
Process Mapping
Process Mapping
Process Mapping
Process Mapping
Chronological Order
Process Mapping
Customer
Order Process
Planning
Production
Time
Distance
Process Mapping
Example:
orders
Go pick-up
Process Mapping
Task description
Inventory or queue
Receive
orders
Go pick-up
= 3 CT=30
Process Mapping
Rush
Normal
Process Mapping
What
type of
order is
it?
CT=30
Normal
60%
Process Mapping
Lag, lead
and/or
queue time
or
No lag, lead
and/or
queue time
Process Mapping
Check Order
Check Order
Request Date
Part No.
Quantity
Billing Address
Shipping
Address
=3 CT=30600
Tells us nothing!
CT varies depending
on clarity and
completeness
Process Mapping
Enter data on
our screen
80%
20%
No
=1 CT =
15
Process Mapping
Is order
informati
on
complete
Yes
?
80%
20%
No
If we have an alternate
path, no is not
complete
Enter data on
our screen
=1 CT =
15
Process Mapping
Process Mapping
80%
Enter data on
our screen
=1 CT =
15
No
20%
Copy of
electronic
form highlighted
with fields
entered
xxxxxxxxxx
xxx
Process Mapping
Process Mapping
Example: an observant
team might have seen
this was done without a
checklist just from
memory
Check Order
Process Mapping
Chronological Order
Process Mapping
Customer
Order Process
Planning
Production
Time
Distance
Continue to . . .
Describe each activity on a stickie and attach to
the appropriate location
Keep activities in sequence
Stick to the scale
Connect activities using a non-permanent marker
Process Mapping
Observe
Document
Process Mapping
Chronological Order
Process Mapping
1. After documenting reality, identify waste by labeling
each stickie as VA/NVA using colored markers/dots
2. Analyze map & capture problems/issues/opportunities on
the to-do list;
1. Look at VA/NVA, handoffs, time lags, queues,
inventory, inspections, duplication/rework and
clarification loops
3. List lean countermeasure for each item on the to-do list;
make assignments
4. Some teams create an ideal process map for the Least
Waste Way (at consultant discretion)
With a bias for action, implement
countermeasures
--
Just
Do
It!
--
Process Mapping
Optional enhancements
Can be used in addition to basic process
mapping if it significantly helps
progress/ bias for action of the
improvement activity
Process Mapping
Tool SIPOC Map
High level process map
Helps frame problem
Effective communication tool to management
Suppliers
Inputs
Outputs
Process
Start
Boundary
Detailed Process
Map
End
Boundary
Customers
Process Mapping
Inputs
Outputs
Customers
Grocery Store 1
Peanut Butter
Fried PB Sandwich
Elvis
Grocery Store 2
Bread/Butter
Appliance Store
Stove
Power Company
Electricity
Kitchen Store
Skillet/Knife
Items
Gathered
in
Kitchen
Spread PB
on Bread
Process
Assemble
Sandwich
Spread
Butter on
Sandwich
Fry
Sandwich
Sandwich
on Plate
for Elvis
Process Mapping
Process Mapping
ASME Symbols Usage
PROCESS STEP INFORMATION REQUIRED
Operation
Inspection
Formal Store
Transport
Delay/Temporary
Storage
Process Mapping
ASME Symbols Usage
Value Added
Non-Value
Added
Non-Value
Added
Non-Value
Added
Non-Value
Added
Non-Value
Added
Process Mapping
ASME Symbols Usage Visual
Process Mapping
Alternative Types Overview
Value
Added
Activities
Non-Value
Added
Activities
Three
Dimensional
Cost Line
Avg.
20.50
8.00
Lift
9.00
Cum.
3.25 7.75 9.75
30.2538.25
Second
Floor
47.25
Docume
nt
Request
First
Floor
Finished
Doc.
sent off
Process Mapping
Remember
Used primarily to document reality on
business processes
Used to visually describe the process
Team selection and use of non-leading
questions are critical
Also used to identify waste/problems and
implement countermeasures
Process Mapping
GR - Process Mapping.ppt
41
Process Mapping
Process Map Exercise Paying Your
Monthly Bills
Pay
Consumer
Any Co.
Consumer
Any Co.
Postal
Service
Consumer
Bill
Send
Payment
Notice
Receive
Payment
Receive
Bill
Write
Check
Mail
Payment
You have 30 minutes to develop the next level process map, 5 minutes to
summarize experience and learnings, 3 minutes to report on your experience
Process Info - Notices are mailed monthly; you get mail every day, but not bills
every day; you pay bills weekly; bill notices and payments are mailed thru the
postal service; payments are made by personal check; there are 3 participants
in the process Any Co., Postal Service, You the consumer
Task - Create the next level process map for the previous level process steps
Show - Decision points, points with variation, Loop Backs, Time Line, Queue
points and quantity, Hand-offs
Process Mapping
GR - Process Mapping.ppt
43
Process Mapping
Typical Example of The Detailed Process Map
Process
Invoice
Print Place in
Invoice
Mail
Pick-up
Mail
to
Post
Office
Take
Run
mail
route
Put mail
In box
Get
Mail
Sort
for
Bills
time to
Pay
bills?
Put bills
In desk
Y
Retrieve
bill
Review
bill
Is bill
correct?
N
Call
Any Co
Days to Process
0
10
12
Process Mapping
Typical Example of The Detailed Process Map
Pick-up
Mail
Put bills
In desk
N
Money in
checking?
Put
money
In
checking
Put bills
In desk
Buy
envelopes
Put bills
In desk
Write
Check
Buy
Stamps
N
Place check
& Invoice in
Have
envelopes?
Y
Have
stamps?
envelope
Put
Stamp on
Envelope
Put in
mail
Days to Process
14
16
18
20
22
24
26
Process Mapping
Typical Example of The Detailed Process Map
Receive
Payment
Take to
Post
Office
Run mail
route
Put mail
In box
Days to Process
26
28
30
32
34
Process Mapping
Typical Example of The Detailed Process Map
Process
Invoice
Print Place in
Invoice
Mail
Pick-up
Mail
Receive
Payment
to
Run mail Put mail
Post
route
In box
Office
Take
Pick-up
Mail
N
Sort for
Get Mail
Is it time to
Bills
Pay bills?
Take to
Post
Office
Run mail
route
Put mail
In box
Put bills
In desk
Y
Put bills Put money
In desk In checking
Is bill
correct?
Y
Retrieve Review
bills
bill
Money in
checking?
Write
Have
Check envelopes?
Place check
& Invoice in
envelope
Put
Stamp on
Envelope
Have
stamps?
Mail
Payment
Call
Any Co
Days to Process
0
10
15
20
25
30