Process Mapping
2
Provide an overview of Process Mapping
Show a step-by-step example Demonstrate where Process Mapping
fits into the DMAIC Process Improvement Model
Show types & utilization of process mapping
Provide a Cookbook Perform a Process Mapping exercise Analyze a process for Non-Value
Added steps
Process Mapping
3
Understand the Process
Develop and Evaluate Measurement Systems
q Data Collection Plans
q Continuous MSA (Gage R&R)
q Attribute MSA (Kappa Studies)
q Data Integrity
Evaluate Risks on Process Inputs q FMEA
q Process Capability
ü Current State Process Maps
ü Identified and measured X’s (KPIV’s)
ü Measurement system verified
ü Current capability of Y’s (KPOV’s)
Tools Steps Outputs
Measure q Understand the
Process
q Evaluate Risks on Process Inputs
q Develop and Evaluate Measurement Systems
q Measure Current Process Performance
Measure Current Process Performance
q SIPOC / VSM q Input/Output
Analysis q C&E Matrix q Detailed Process
Maps
Measure
4
What is the tool? - Graphical illustration of the
work process
What will the tool identify? - All value-added and non-
value-added process steps
- Process Inputs (X’s)
- Process Outputs (Y’s)
- Data Collection Points - First Input Variables to put in
FMEA
What are results of Process Mapping? - Identify systems needing
Measurement Studies
- Identify Output Variables for Capability Studies
- Identify missing elements in the Control Plan
- Identify possible non-value- added process steps
Process Mapping Overview
5
Process Mapping Overview
When to do Process Mapping?
To do or not to do?…..
ANSWER:
At the beginning!!!
Always!!!
And
Again and Again!!!
6
Should describe:
- Major activities / tasks
- Sub-processes
- Process Boundaries - Input Variables (X’s)
- Output Variables (Y’s) Should be reviewed frequently and updated
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Process Mapping
7
The Funneling Effect
30+ Inputs • SIPOC & Process Mapping • C&E Matrix • Failure Modes & Effects
Analysis
MEASURE All X’s
1st “Hit List”
10 - 15 • Multi-Vari Studies ANALYZE Screened List
6 - 10 • Design of Experiments (DOE) IMPROVE Found Critical X’s
3 - 6
Critical Input Variables