What is a Process Map?
A picture of the sequence of steps in a process
Process Maps can show these 4 things
- The process as a whole
- The sequence of steps
- The relationship between steps
- The starting and ending steps of the process
What 8 Steps are used to Create a Process Map?
- Select a Process
- Identify the people who work in the process to gather their input
- Identify the start and end points of the process
- Map the process by creating a rectangle shape for the first step and labeling it
- for every step, create additional rectangles with labels
- For steps where a decision is made, use a diamond shape
- Continue until you have reached the last step of the process
- Connect the shapes using arrows to illustrate the flow of the process
Why is “Seeing” My Process Important?
- Experience changes the way you view the process
- Allows you to gather clues to solve your problem
- Change the process to change the result
What 3 steps should be followed to “See” My Process
- Start at the beginning of the process
- Walk through the sequence of steps to completion
- Observe what happens at each step
What is a Process Walk
- Process Map guides a Process Walk
- A tour of the area where work takes place
- Includes a series of observations and sometimes interviews
- Find opportunities and understand the work
What are Loopbacks?
- Something hasn’t gone correctly in the process
- Work needs to be redone and started over
What is Waste?
Anything that ineffectively consumes resources, space and time
What are the 8 Wastes
- Defects
- Overproduction
- Waiting
- Non-Utilized Talent
- Transportation
- Inventory
- Motion
- Extra Processing
What is the Waste of Defects
Any time something other than the exact desired result happens
What is the Waste of Overproduction
- Producing something more or sooner than needed
- Creates additional waste of inventory
What is the Waste of Waiting
- When work is unable to proceed because something is unavailable
- Can result in wasted labor, delayed work and increased cycle time
What is the Waste of Non-Utilized Talent
Not properly utilizing people’s experience, skills or creativity
What is the Waste of Transportation
Excessive movement of things, such as materials, products or tools
What is the Waste of Inventory
More than the amount of supplies needed for the current work
What is the Waste of Motion
Excess movement of people
What is the Waste of Extra Processing
Additional work that is done beyond what is truly needed
What are some other Process Issues?
- Handoffs
- Approvals
- Preparations and Setup
- Reports
What are the 4 Steps to perform your Process Walk
- Pick your process
- Create your Process Map
- Walk your process
- Summarize your observations
Process Walk: Step 1 - Identify your Process
- Pick a process that you are involved in
- Work within your department
- Identify the beginning and ending of the process within your department
- What event causes the process to start?
Process Walk: Step 2 - Create Your Process Map
- Write down what action happens first
- Write down steps that happen after
- Repeat until the last step within your department is reached
Process Walk: Step 3 - Walk Your Process
- Follow your Process Map
- Observe what happens
- Ask Questions
- Does the actual process math the process map
- Are there any disruptions? Wastes? Opportunities? Clutter?
Process Walk: Step 4 - Summarize Your Observations
- Update the Process Map
- Evaluate and prioritize the waste
- Note their impact
