Flowcharting

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Continuous Improvement Toolkit

Flowcharting


Check Sheets

Data Collection

Process Mapping Flowcharting

Flow Process Charts

5S

Value Stream Mapping

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Mistake Proofing

Tree Diagram*

Understanding Performance

Fishbone Diagram

Design of Experiment

Implementing Solutions**

Creating Ideas

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Decision Tree

Force Field Analysis Cost Benefit Analysis

Voting

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PDPC

RAID Log*

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IDEF0

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Importance-Urgency Mapping

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Benchmarking**

SCAMPER**

C&E Matrix

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Critical-to Tree

Paired Comparison

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Interviews

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Graphical Analysis

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Hypothesis Testing

Visual Management

Ergonomics

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Cross Training

How-How Diagram**

Flow

Time Value Map

ANOVA

Gap Analysis*

Traffic Light Assessment

TPN Analysis

Decision Balance Sheet

Suggestion systems

Risk Assessment*

Automation Simulation

Break-even Analysis

Service Blueprints

DMAIC

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Data collection planner*

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Probability Distributions

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MSA

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Process Yield

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Pick Chart

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Pull

OEE

Mind Mapping*

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Correlation Scatter Plots Regression

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Activity Networks RACI Matrix

PERT/CPM Daily Planning

MOST

Standard work Document control A3 Thinking

The Continuous Improvement Map

Multi vari Studies


A diagram that shows how the steps in a process fit together.

Breaks any process down into individual activities.

Illustrates the flow of the process and the relationships between its activities.

Useful for understanding processes and finding inefficiencies for further problem-solving efforts.

Often used to provide a detailed view of how a process should be.

- Flowcharting

Good?

Make

Scrap

Process

Start

Yes

No


Useful for communicating the sequence of activities and how a process works.

Often used for documenting how to do a particular job. • Can be found in procedures and quality manuals.

• Helps understand the activities and decisions and thus perform the tasks correctly and in the right order.

Also used when designing processes and programs. • Software developers can use them to map processes that need to

be automated.

- Flowcharting


Constructing flowcharts promotes better understanding of processes by all participants of a problem-solving team.

Teams can use them to identify and analyze problem areas and provide insight in order to: • Simplify work.

• Reduce cycle times.

• Troubleshoot a problem.

• Improve or redesign the process.

They help investigating the performance of a process.

They can reveal areas of inefficiency such as unnecessary activities and excessive delays.

- Flowcharting


Common Process Problems:

Errors and rework.

Unnecessary activities and duplication.

Bottlenecks.

Long cycle times and excessive delays.

Missing and unclear steps.

Too many inspections or checks.

Complex procedures.

Departure from procedure.

Dead ends.

Costly steps.

Nov-value adding steps.

-- Flowcharting

Muda


Typically drawn with arrows and shapes of various kinds.

There is no specific format for a flowchart.

• There must be an agreement of the used symbols.

• They should be drawn in a consistent manner.

• Check your company for any standard set of symbols that you should comply with.

- Flowcharting

Process


The Most Common Symbols:

A process step which represents an activity. • denoted as a rectangular box.

• In most flowcharts this will be the most frequently used symbol.

A decision which represents a decision point. • denoted as a diamond.

• This symbol will require a yes/no response.

The start and the end of a process. • denoted as ovals.

Arrows that connect the symbols and show process flow.

- Flowcharting

Process step

Start / End

Decision

Process flow


You may use other symbols to describe the type of activities in the chart more clearly.

Keep things simple to gain people’s understanding.

Colors and shading can be used to call attention to different types and steps.

Some flowcharts show more information: • Who is responsible for each specific step.

• How much time each step takes.

• …

- Flowcharting


Flowcharts can be created for many different levels of the process.

A single flowchart can quickly becomes long and complicated.

You may need to represent everything in more than one flowchart.

Nested flowcharts can be created for this purpose.

Connectors:

• Can be used to link sub-processes.

• Often denoted as numbered circles together.

- Flowcharting


A Cross-Functional Flowchart is a diagram that shows all steps and their logical sequence arranged per department or function.

This type of flowchart is divided into different “lanes”.

It demonstrates the control of the different departments on each process step.

It allows to clarify the responsibility for performing an action or making a decision.

- Flowcharting

1

2

3


How to Construct a Flowchart: Describe the process and its objectives.

Determine the level of detail, the scope and the boundaries of the chart.

Identify all major process steps, decisions and the sequence of completion.

Draft a flowchart using the standard set of symbols.

Label each symbol appropriately.

Prepare the final flowchart and add further details as necessary.

Test the flowchart to make sure that it represents the process accurately and completely.

Identify problem areas and improvement opportunities.

- Flowcharting


Example – Changeover Operation (Size Conversion):

- Flowcharting

Start

Specify customer

requirement

Communicate Changeover

requirements

Prepare tooling and spare parts

Implement changeover operations

Trial run and measure main

parameters

Specs. Met?

End Run the line

Adjust settings

Stop the line

Specs. met?

Yes

No


Example – Acquiring New Equipment:

- Flowcharting

Start

Define needs

IT

Finance

Purchasing

Business Unit Prepare

paperwork

Technical review

Approved?

Approved?

Acquire equipment

Configure and install

Specs. Met?

Received? Follow-up

with supplier

Issue payment

Receive and use

End

No

Yes

Yes

No

Yes

No


Further Information:

The exercise of flowcharting internal processes can clarify your and your team’s understanding of their work.

It’s always a good practice to walk the process before you draw your flowchart to get an overview of the process and identify the boundaries.

Although you can draw flowcharts by hand, it’s often convenient to use any drawing program to create visually appealing flowcharts. Some applications even offer special support for flowchart drawing.

Flowcharts showing steps that are visible to the customer are considered service blueprints.

- Flowcharting


Further Information:

What do we think of a process is not necessary what it actually is.

- Flowcharting

What you think it is… What it actually is… What you would like it to be…

Hidden factors

Flowcharting

Leadership & Management