Process Mapping
Learning Objectives
By the end of this module participants should be
able to:
• Identify the importance of process mapping
• Identify the four different types of process mapping
• Develop a detailed process map
• Explain the value of Functional Process Maps
The DMAIC Process with Tools
DAY 1
Define
PHASE 1&2
Measure
Tools:
• Voice of Customer (VOC) Analysis
• Process Mapping
Analyze • Value Stream Mapping
Improve
Control
Importance of Process Mapping
Possible benefits
• Document and understand the actual process
• Show the relationship of Process Steps
• Develop a list of potential Xs to assist in building Y = f(X)
• Determine Value-Added (VA), Business-Value-Added (BVA),
and Non-Value-Added (NVA) steps of a process
• Communicate information
• Train employees on the process
Characteristics of
Value Stream Map
What Is A Process Map?
A Process Map is a
graphical
representation of the
steps involved in a
process or portion of a
process
What is different between Process Mapping and VSM?
Process Mapping ValuePossible
Stream benefits
Mapping
• A Process Map is a graphical • A pictorial representation
representation of the steps of the Flow of Material
involved in a process or People and Processes
portion of a process Information
• There are many types of • Specific data associated
Process Maps at different with each step
levels of detail and used for Touch Time and Cycle Time
different purposes. Some of Volume
Resources
the more typical are:
Errors/rework
4 Types of the Process Map
High-Level Common Detailed Functional
Used in Used to Adds inputs/ Breaks the
project display the outputs, VA/ steps into
definition steps in the BVA/NVA, functional
and scoping process. and areas,
- e.g., SIPOC First step in classification frequently
constructing of inputs to mapped
a Detailed the Common against a
Map Process Map time line
-eg., Value
Stream/Detailed
Process Map
Versions Of A Process
Possible benefits
At Least Three Versions
What you think it is... What it actually is... What you would
like it to be...
Levels Of A Process
Business Business Core
Development Functional
Process
Departments
(“Strategic”)
Business Sales Underwriting Contracting
Customer
Processes Service
Sub-process
High-level Customer
Supplier TermsTerms Docs Negotiate Close
Process Map
(ext.) Customers
Underwriters (int.) Cust.
Service Dept.
Detailed
Detailed
Sub-process Map Sub-process
Tasks Procedures
SIPOC – A High-level Process Map
(Covered In Project Definition Module)
A High-level Process Map
should describe:
• Major tasks and activities
SIPOC: Supplier, Inputs, Process, Outputs,
• The boundaries of the process
• The Process Output Variables Customers.
(POV)
• Who receives the outputs
(customers)
• What does the customer require
of the outputs
S : Supplier
• The Process Input Variables (PIV) I : Inputs
• Who supplies the inputs
(suppliers)
P : Process
• What does the process require O : Outputs
of the inputs
C : Customers
Common Process Map
A common Process Map should describe:
• All of the steps within the bounded process
• The flow relationship between the steps including loops
and\decision points
• Distribution of material flow
• This is a first step in building a detailed Process Map
This is sometimes referred to as a simple Flowchart.
Common Process Map Example
Detailed Process Map
A detailed Process Map should describe:
• All of the steps within the scope of the project (frequently a subset of what
was mapped in the common Process Map)
• The flow relationship between the steps including loops and
decision points
• Distribution of material flow
• All inputs and outputs by step
• The Value-Add status of each step – VA, BVA, or NVA
One of the best tools to develop the list of PIVs.
Detailed Process Map Example
Detailed Process Map Example
Tips In Process Mapping
1. Clarify process boundaries
2. Use verbs to describe steps
3. Do not include “who” in step description
4. Combine, eliminate duplicates, clarify steps
5. Analyze/review from finish to start
6. Process Mapping is best done as a team
7. Involve stakeholders
8. Cross-functional teams are generally recommended
9. “Walk the process”, repeatedly
10. Ask lots of questions
11. Map the process at the “right” level
Exercise # 1: Process Mapping
What Level Of Magnification Is Required?
High-level Maps provide:
60,000 foot view of the process
Inputs, outputs, customers, suppliers (at macro level)
Mid-Level Maps provide:
Clear view of all steps in the process
Sequence of steps, loops, etc
Detailed Maps provide:
Evaluation of Value-Add status for all steps within the bounded
or confined area of the process
Inputs, outputs for all steps within confined area of the process
Definitions – Activity Types
Value-Added
Any activity or task that transforms the deliverables of a process in
such a way that the client is aware of it and is willing to pay for it
Any activity that, when left out, would impact product
performance and/or customer satisfaction
Business-Value-Added
Necessary to support Value-Added steps in the current process
Includes those activities that do not add value but are currently
required by regulation or law
When left out, may not directly impact the customer or
incur dissatisfaction
Non-Value-Added
Any activity that, when left out, does not directly impact the
customer or the business
Definitions – Input Types
Controllable (C)
These are inputs that you can adjust or control while the process is
being setup or running, e.g., speed, feed rate, temperature, pressure.
These are sometime referred to as “knob” variables
Standard Operating Procedures (S)
These are procedures that are part of the process and have been
defined and documented. The goal here is to make sure that we
document the true procedure, e.g., cleaning, safety, loading of
components, setup
Noise (N)
These are things you cannot control or choose not to control due to
cost or difficulty, e.g., ambient temperature or humidity, operator
training
Process Mapping The 8 Step Methodology
1. Create the Top Level SIPOC, defining the scope of the process
(start and end)
2. Map all activities needed in the production of a “good”
product or service within the scope from Step 1
3. If desired narrow the focus to that portion of the map that is
critical to the project
4. For the activities from Step 3, designate as VA, BVA, or NVA
5. List outputs for each activity from Step 3
6. List inputs for each activity from Step 3
7. Classify all inputs as C, S, or N
8. Clearly identify all data collection points
Why List The Inputs And Outputs?
• Project improvements are based on finding Y = f(X)
• Must have a list of potential Xs to start the investigation
• The Process Map is an excellent tool for identifying
potential Xs
• Outputs from one Process Step are usually the inputs
for the next
Process Step
To identify the list of potential Xs or PIVs, fill the top of the funnel.
Links To Other Tools
The detailed Process Map provides input to:
• Cause and Effects Matrix
• Failure Mode and Effects Analysis (FMEA)
• Control Plan
• Multi-Varied Studies
• DOE planning
Summary
Process mapping shows the relationship of process steps.
There are 4 different types of process maps such as;
high-level,
common,
detailed, and
functional
A functional process map describes the steps in the
bounded process, separated into functional areas and
internal customer-supplier relationships.
Thank You