Kpiv and kpov template excel

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

•  Control Plans CONTROL* Controlling Critical X’s

8

  Team Effort – Manufacturing Example: -  Manufacturing engineers -  Line operators -  Line supervisors -  Maintenance technicians -  Suppliers

  Inputs to Mapping -  Brainstorming -  Manuals, work instructions -  Engineering specifications -  Operator experience -  Fishbone diagrams (6 Ms)

•  Transactional Example: -  Sales force -  Engineers -  Operators -  Supervisors

Preparing the Process Map

9

  Identify the process in basic terms   Identify External Supplier (Inputs) -  Raw materials

-  Incoming information

-  Personnel

  Identify the Customer Requirements (Outputs) -  Process or Product customer specifications or critical

attributes. -  Business/Organization Performance metrics.

(We need to get a “high level” view of the process first)

SIPOC

10

Order Entry Phone FAX Email EDI

Price Availability Confirmation of

Order Promise Date Order number

Inputs Outputs

Non- Manufacturing

Manufacturing