Professional Documents
Culture Documents
Process Mapping
Module Objectives
What You Think It Is... What It Actually Is... What You Would
Like It To Be...
Levels Of A Process
Business Business
Process Development
(“Strategic”)
Business Customer
Sales Underwriting Contracting
Processes Service
High Level
Supplier Terms Docs Negotiate Close Customer
Process Map
(ext.) Customers
Underwriters (int.) Cust. Service Dept.
Detailed
Sub-Process
Map
Tasks Procedures
Process Map
Should describe
- Major Activities / Tasks
- Sub-processes
- Process Boundaries
- Process Input Variables (Xs)
- Process Output Variables (Ys)
- Customers & Suppliers
SIPOC Benefits
Includes information:
- necessary to balance competing customer requirements
- identify “gaps”
- verify team and information resource requirements
Requirements Requirements
S I P O C
Suppliers Inputs Process Outputs Customers
Input Boundary Output Boundary
New
Employment
Process
SIPOC Business Process Example:
Identify Customers of the Process
New
Customers
Employment
Process Manager
Co-workers
External Customers
Other Departments
SIPOC Business Process Example:
Identify Outputs & Link With
Customers
New
Output Customers
Employment
Process New Employee Manager
Co-workers
External Customers
Other Departments
SIPOC Business Process Example:
Identify Suppliers to the Process
New
Suppliers Output Customers
Employment
Executive Process New Employee Manager
Committee
Co-workers
Department
Managers External Customers
Etc.
SIPOC Business Process Example:
Identify Inputs Linked with
Suppliers
New
Suppliers Input Output Customers
Employment
Executive Manpower Need Process New Employee Manager
Committee
Hiring Budgets Co-workers
Department
Managers Requisition External
Customers
Recruiters Job Descriptions
Other
Etc. Candidates Departments
SIPOC Business Process Example:
New
Suppliers Input Output Customers
Employment
Executive Manpower Need Process New Employee Manager
Committee
Hiring Budgets Co-workers
Department
Managers Requisition External
Customers
Recruiters Job Descriptions
Other
Etc. Candidates Departments
Business Process SIPOC Exercise
(15 min.)
(5 min. debrief)
Catapult SIPOC Exercise
(15 min.)
(5 min. debrief)
S I P O C
Suppliers Inputs Process Outputs Customers
(Providers of (Resources ( Top level (Deliverables (Anyone who
the required required by description of from the receives a deliverable
resources) the process) activity) process) from the process)
Requirements Requirements
What does the
process expect
What does
Who is the from each Boundary each customer
supplier of input?
expect from
each input?
When does the each output?
What are the
process start?
outputs from
the process?
What Inputs are
required to
enable this
process to What is the
occur? process? Who is the
customer of
each output?
Boundary
SIPOC Business Process Example
Excel Method
Qualified Manager
Executive Committee Manpower Needs
Fits xyz
Hiring Budgets culture
Co-worker
Oriented to
Requisition New Employment Hiring Business
New Employee
Department Managers Process
Setup for Other
payroll benefits Departments
Job Descriptions
Recruiters Qualified
Candidates External
Customer Customers
Focused
Detailed Process
Mapping
Detailed Process Mapping Symbols
– Delay (Red)
– Storage (Yellow)
– Decision (Blue)
BK1-2PROCESS MAP
Basic Structure
Scrap
Bad
Bad
Good
Good
• How many Process or Operation Steps are there?
• How many Decision Points?
• How many Measurement / Inspection Points?
• Where are the Bottlenecks?
• How many Re-work Loops?
Warehouse
Definitions
VALUE ADDED
Any activity, when left out, that does not directly impact
the customer and may incur no dissatisfaction
- These steps may be necessary to support VALUE ADDED steps
however
Process Mapping Steps
5 Easy Steps
Why List the Inputs and Outputs?
To reduce defects!
Input Classifications
Cooking
Suppliers Input Output Customers
Pasta
Restaurant Owner Raw Pasta Cooked Patrons
Grocery Store Pan Owner
Pasta
H2O Cook
Cup
Stove
Spoon
Salt
Oil
Step 2 Example :
Identify All Process Steps
No
.5 MINUTE 6 MINUTES .25 MINUTE 9 MINUTES
No
.5 MINUTE 6 MINUTES .25 MINUTE 9 MINUTES
Rework
Pasta Process Map
.01 DPU
No
.5 MINUTE 6 MINUTES .25 MINUTE 9 MINUTES
Rework
Pasta Process Map
.01 DPU
No
.5 MINUTE 6 MINUTES .25 MINUTE 9 MINUTES
No
.5 MINUTE 6 MINUTES .25 MINUTE 9 MINUTES
Value
Added/
Non
value
Input Type Process Added Output
Add water,
salt and
Amount of water Controllable water VA Ingredients added
Amount of salt Controllable CT=.5 minutes
Amount of oil Controllable DPU=?
Pasta instructions SOP COPQ=?
Brainstorm steps
- Use verbs
(45 min.)
(15 min. debrief)
Team members
Time and scheduling
Method
Involve stakeholders
Multiple opinions
- Customers – Specifications
•Depth
•Accuracy
–Incorrect information
–Too much detail
–Too little detail
Additional Maps
Common flowchart
Top-down flowchart
Others
Help
Start Snooze Wait Kids
No No No
Wake Bath Free
Ready? Shower Kids Ready
Up
Yes ? Yes ?
Yes
OK Wave
Eat Drive Traffic? Go Late? To
No Boss
Heavy Yes
Change
Route
Sneak
In
Stop
Top-Down Flowchart
Review &
Configure
I.T.
approve
& install
standard
Procure- Top Mgt/ Finances
Review &
approve
Acquire
ment
equipment
Supplier Supplier
17
21 days 6 days 15 days 5 days days 7 days 71 days
Links to Other Tools
SIPOC
Process Mapping
Input classification
VA / NVA
Module Objectives Review
Request is put
• Checklist Incomplete
into Checklist rotation • 1 Day - 21 Days
Yes
BK1-2PROCESS MAP
Corrective Action Guidelines
Start
• Used to determine
Wrong
Fix Battery Position Battery Pos.
cause of failures OK
• Troubleshooting Yes
Light ?
No
Bad
Replace Battery Test Battery
OK
Yes No
Light ?
Bad
Replace Bulb Test Bulb
OK
Payable
Advance Purchase
Seller Settlement
Seller on Agreement
ID #
Purchase #
Settlement
Agreement
to Purchase
Deliveries
Another Industrial Engineering
Example
Deliverable Generic Widget Product
Process Total Manaufacturing
Champion Joe Toofast
Department ABC
Organization XYZ
Project NA
Facility Idaho
Step Step Description Work Verify Fix Move Delay Store Unit Description Dist Time OP
1 Receive steel X Steel bar stock 37.2
2 Perform inspection X 5.5
3 Complete documentation X 1.4
4 Transport to cut-off X 237 5.3
5 Execute cut-off operation X Steel cube stock 7.7
6 Perform inspection X 1.5
7 Rework as required X 4.6
8 Complete documentation X 0.5
9 Transport to milling X 382 11.4
10 Execute milling operation X Finished part 5.6
11 Perform inspection X 1.2
12 Rework as required X 1.5
13 Complete documentation X 0.5
14 Transport to assembly X 265 8.7
15 Execute assembly operation X Finished Widget 1.7
16 Perform inspection X 0.3
17 Rework as required X 0.8
18 Complete documentation X 2.5
19 Transport to shipping X 478 12.4
Total = 3 4 3 4 4 1 1,362 110.3
Efficency = 16%