How to Develop a Process Map

One of the most important steps in the Six Sigma process is Process Mapping. Process Mapping is basically the development of a graphical representation of your current process. This tool (Process Mapping) should almost always be employed in a Six Sigma project. We will use the tool of Process Mapping to help us identify value-added and non-value-added activities and process steps that include the Input Variables and the Output Variables. The Process Map will also identify the points at which we collect data and make transactions. What we hope to achieve in Process Mapping is the identification of output variables that may require capability studies and possible elimination of non-value added steps in a "Future State" Process Map.

Things You'll Need

• Manufacturing engineers
• Line operators
• Line supervisors
• Maintenance technicians
• Suppliers
• Safety professionals
• Operator manuals
• Engineering specifications
• Operator experience

Instructions

1. Identify the Process Inputs and Customer Requirements:
   The inputs may include Raw materials energy requirements, incoming information and the personnel required to complete a certain job.
   After identifying the inputs we must understand what the Customer Requirements are to be able to relate them to the specification of the outputs.

2. Next we must identify all of the Steps in the Process to develop a sequence. The sequence of the process is just as important as the individual process steps. What we would like to be able to do is include value-added and non value-added steps in our Process Map. In a manufacturing process, examples of the steps may include information transactions to begin the process, material movement/placement, raw material processing, component fabrication, assembly, inspection/test, rework and scrap points and order fulfillment. Within each step of the Process Map there may be waste that is easily identified, make a note of any waste (Non-Value Added Activity) for later analysis.

3. List the Key Output Variables of the process. The Key Output Variables are basically the product or outcome of your process steps. Each one of the process steps in your Process Map may have a Key Out Variable. The Key Output Variables are what we would like to later analyze to determine process capability. This would include process capability analysis for each step and the overall process.

4. We can now classify the Key Input Variables as either "controllable", non-controllable or critical. Controllable Input Variables can be changed to see the effect on Output Variables. At this point the critical input variables may be uncontrollable and identified as such for later efforts to gain control. You can start to see how a Process Map leads to further work and application of other Six Sigma tools and methods.

5. Now finally we can add specifications to the outputs to drive expectations of the process. This will help us later when we develop control plans and do capability studies. Without a clear definition (specification) of the final product the process can not be improved.

Tips & Warnings

• There are several levels of Process Maps that can be created but usually a good Process Map requires a full cross functional team of process experts.

• Use the Process Map to identify areas for improvement by quantifying each step in the process.