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Process Mapping The Key To Continuous Improvement Bob Wallner, CPIM Lean Leader New Hampshire Ball Bearing HiTech Division
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Process Mapping - SectionProcess+Mappin… · • Process mapping is a – simple & visual ... – Understand how your process map will help ... • Data layered on our process map

Jun 09, 2018

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Page 1: Process Mapping - SectionProcess+Mappin… · • Process mapping is a – simple & visual ... – Understand how your process map will help ... • Data layered on our process map

Process Mapping The Key To Continuous Improvement

Bob Wallner, CPIMLean Leader

New Hampshire Ball Bearing HiTech

Division

Page 2: Process Mapping - SectionProcess+Mappin… · • Process mapping is a – simple & visual ... – Understand how your process map will help ... • Data layered on our process map

My Background With Continuous  Improvement Mapping

• Majority of my experience is Supply Chain  responsibility

• 1999 was on management team to move to  ISO9000:2000

• 2001 – 1st Lean exposure was seminar while  working for a company that embraced Industrial 

Manufacturing • 2003 – Began my lean journey by participating 1st

Kaizen as a “Champion”• 2003 –

Today work to incorporate process 

thinking into my everyday job

Page 3: Process Mapping - SectionProcess+Mappin… · • Process mapping is a – simple & visual ... – Understand how your process map will help ... • Data layered on our process map

Team EinsteinTeam Vern

– Technically Minded?

– Engineer Solutions?– Who can visualize the 

difference between  .001”

& .0001”

– Less Technically  Minded?

– Have ideas but need someone else to 

engineer them?

– Need to see to  situation to fully 

understand?

Both teams are part of your company!Both teams need to understand the problems 

facing your company!

Page 4: Process Mapping - SectionProcess+Mappin… · • Process mapping is a – simple & visual ... – Understand how your process map will help ... • Data layered on our process map

Communication begets Kaizen

Technical and non‐technical people, have to  communicate in a common language for 

kaizen to occur.

PROCESS MAPS CAN HELP BRIDGE THIS GAP!

Page 5: Process Mapping - SectionProcess+Mappin… · • Process mapping is a – simple & visual ... – Understand how your process map will help ... • Data layered on our process map

My definition of Process Mapping

• Process mapping is a – simple & visual tool; 

– used to understand & communicate 

– the flow of work & information across an  observed work flow.  

Page 6: Process Mapping - SectionProcess+Mappin… · • Process mapping is a – simple & visual ... – Understand how your process map will help ... • Data layered on our process map

Where do we start?

Page 7: Process Mapping - SectionProcess+Mappin… · • Process mapping is a – simple & visual ... – Understand how your process map will help ... • Data layered on our process map

Process Mapping Steps

1.

Identify Who, What, Why, When & Where

Page 8: Process Mapping - SectionProcess+Mappin… · • Process mapping is a – simple & visual ... – Understand how your process map will help ... • Data layered on our process map

When beginning we need to know

• Who are we trying to communicate to?– Know your audience/team

• What are we trying to communicate?– Collect only data required– What are expectations for this map

• Why are we trying to communicate it?– Understand your problem statement (Use A3)– Understand how your process map will help you

• When is this map good for?– On going process or one time change?– Is it current state or future state?

• Where is this taking place– Set boundaries (Scope)

Page 9: Process Mapping - SectionProcess+Mappin… · • Process mapping is a – simple & visual ... – Understand how your process map will help ... • Data layered on our process map

Process Mapping Steps

1.

Identify Who, What, Why, When & Where

2.

Create your legend

Page 10: Process Mapping - SectionProcess+Mappin… · • Process mapping is a – simple & visual ... – Understand how your process map will help ... • Data layered on our process map

Create a legend of icons you will use

Critical Icons• Process Steps – Work Being Done• Decision Tree – Branches for either/or decisions• Connectors/Work Flow – What processes are linked and 

what direction do they flow

Optional Icons• Documents – What documents, reports or metrics are 

used or needed• Outside/Sub Processes –

Processes

that are outside of 

scope of map but need reference• Data – Time, Pieces, Steps, Failures, Cost, etc• Swim lanes – divide work by logical grouping or output• Any other info that is valuable to your problem statement

Page 11: Process Mapping - SectionProcess+Mappin… · • Process mapping is a – simple & visual ... – Understand how your process map will help ... • Data layered on our process map

Process Mapping Steps

1.

Identify Who, What, Why, When & Where

2.

Create your legend

3.

Find your starting point and “Just Do It”1.

Create your map

Page 12: Process Mapping - SectionProcess+Mappin… · • Process mapping is a – simple & visual ... – Understand how your process map will help ... • Data layered on our process map

Just Do It

Page 13: Process Mapping - SectionProcess+Mappin… · • Process mapping is a – simple & visual ... – Understand how your process map will help ... • Data layered on our process map

Create the map 2 step process

1.

If possible ‐

map the process without walking it.1.

Use group to explain the process

2.

Use standard procedures, routers, etc to map what  is “supposed to happen”

2.

Walk the map/process1.

Were steps missed or added?  Why?

2.

Were the steps out of sequence?  Was standardized  work in‐place?

3.

Make observations & Collect data

Page 14: Process Mapping - SectionProcess+Mappin… · • Process mapping is a – simple & visual ... – Understand how your process map will help ... • Data layered on our process map

Process Mapping Steps

1.

Identify Who, What, Why, When & Where

2.

Create your legend

3.

Find your starting point and “Just Do It”1.

Create your map

4.

Regroup with team and review findings1.

Calibrate your team

2.

Correct Map OR Correct Process 

Page 15: Process Mapping - SectionProcess+Mappin… · • Process mapping is a – simple & visual ... – Understand how your process map will help ... • Data layered on our process map

Process Mapping Steps

1.

Identify Who, What, Why, When & Where

2.

Create your legend

3.

Find your starting point and “Just Do It”1.

Create your map

4.

Regroup with team and review findings1.

Calibrate your team

2.

Correct Map OR Correct Process

5.

Use for improvement

Page 16: Process Mapping - SectionProcess+Mappin… · • Process mapping is a – simple & visual ... – Understand how your process map will help ... • Data layered on our process map

PB&J

Sandwiches Current State

Page 17: Process Mapping - SectionProcess+Mappin… · • Process mapping is a – simple & visual ... – Understand how your process map will help ... • Data layered on our process map

Improvement Ideas

• From here the map can be used for many  things.

– Productivity Improvement(Theory of Constraints)

Page 18: Process Mapping - SectionProcess+Mappin… · • Process mapping is a – simple & visual ... – Understand how your process map will help ... • Data layered on our process map

Throughput Issues

1 lot of 

inventory

Running 1  

8hr shiftIn all lines

Page 19: Process Mapping - SectionProcess+Mappin… · • Process mapping is a – simple & visual ... – Understand how your process map will help ... • Data layered on our process map

Productivity Improvement  Theory of Constraints 

Methodology

TOC Improvement Premise

Focus all efforts on exploiting the bottleneck  and restructuring all other processes around 

the bottleneck.

• Looking for bottlenecks and improvement  opportunities to improve throughput

• Where is the inventory stacking up

Page 20: Process Mapping - SectionProcess+Mappin… · • Process mapping is a – simple & visual ... – Understand how your process map will help ... • Data layered on our process map

Throughput Issues

1 lot of 

inventory

Running 1  

8hr shiftIn all lines

Page 21: Process Mapping - SectionProcess+Mappin… · • Process mapping is a – simple & visual ... – Understand how your process map will help ... • Data layered on our process map

Improvement Ideas

• From here the map can be used for many  things.

– Productivity Improvement(Theory of Constraints)

– Waste Elimination

(Lean)

Page 22: Process Mapping - SectionProcess+Mappin… · • Process mapping is a – simple & visual ... – Understand how your process map will help ... • Data layered on our process map

Lead Time Issues

5 Min 3 Min 1 Min 60 Min

5 Min

5 Min

5 Min

2 Sec 7 Sec 2 Sec 1 Min60 Min

2 Sec 5 Sec 3 Sec 60 Min

75 Min

45 Min

5 Min

10 Min

7 Sec 1 Min

1 Min 4 Sec 6 Sec 2 Sec 1 Sec

12 Min5 Sec1 Sec12 hr 1 Min5 Sec

2 Sec

Page 23: Process Mapping - SectionProcess+Mappin… · • Process mapping is a – simple & visual ... – Understand how your process map will help ... • Data layered on our process map

Lead Time Improvement  Lean Methodology

Lean Improvement Premise

Minimize the timeline between when we get an  order from the customer to the time we get 

paid by removing non‐value added activities.

• Identify the Value and Non‐Value activities• Eliminate “TIM WOODS”

Wastes (“Muda”) Definition

Transportation Movement of product that does not add value

Inventory More materials, parts, or products on hand than the customer needs right now

Motion Movement of people that do not add value or may cause injury

Waiting Idle time created when material, information, people, or equipment is not ready

Over Processing Effort that adds no value from the customer’s viewpoint

Over Production Producing more than the customer needs right now

Defects Work that contains errors, rework, mistakes or lacks something necessary

Skills Not utilizing the skills and creativity of your workforce

Page 24: Process Mapping - SectionProcess+Mappin… · • Process mapping is a – simple & visual ... – Understand how your process map will help ... • Data layered on our process map

Lead Time Issues

5 Min 3 Min 1 Min 60 Min

5 Min

5 Min

5 Min

2 Sec 7 Sec 2 Sec 1 Min60 Min

2 Sec 5 Sec 3 Sec 60 Min

75 Min

45 Min

5 Min

10 Min

7 Sec 1 Min

1 Min 4 Sec 6 Sec 2 Sec 1 Sec

12 Min5 Sec1 Sec12 hr 1 Min5 Sec

2 SecWait

Wait

Wait

Wait

Wait

Wait

Wait

Proces

sing

Proces

sing

Proces

sing

Proces

sing

Transp

ort

Transp

ort

Transp

ort

Transp

ort

Transp

ort

Defect

16 Hrs 51 Min Non Value Added 

Time5 Min 14 Sec 

Value Added Time

Page 25: Process Mapping - SectionProcess+Mappin… · • Process mapping is a – simple & visual ... – Understand how your process map will help ... • Data layered on our process map

Improvement Ideas

• From here the map can be used for many  things.

– Productivity Improvement(Theory of Constraints)

– Waste Elimination

(Lean)

– Quality Improvements (Six Sigma)

Page 26: Process Mapping - SectionProcess+Mappin… · • Process mapping is a – simple & visual ... – Understand how your process map will help ... • Data layered on our process map

Defects – Torn Bread

Non Conformance 

found

Page 27: Process Mapping - SectionProcess+Mappin… · • Process mapping is a – simple & visual ... – Understand how your process map will help ... • Data layered on our process map

Yield Improvement Six Sigma 

Methodology

Six Sigma Improvement PremiseUse tools & methodologies to improve the 

quality of process outputs by removing errors  and minimizing process variability.

• Looking for opportunities to improve the  quality yield

• Data layered on our process map can guide us  to where is the defect occurring

Page 28: Process Mapping - SectionProcess+Mappin… · • Process mapping is a – simple & visual ... – Understand how your process map will help ... • Data layered on our process map

Defects – Torn Bread

Non Conformance 

found

Page 29: Process Mapping - SectionProcess+Mappin… · • Process mapping is a – simple & visual ... – Understand how your process map will help ... • Data layered on our process map

Other than Continuous Improvement  What are some other uses for Process  Maps?

Troubleshooting Guides

Spaghetti Diagrams

Work Instruction

Internal Quality Audits

Value Stream Maps

Page 30: Process Mapping - SectionProcess+Mappin… · • Process mapping is a – simple & visual ... – Understand how your process map will help ... • Data layered on our process map

Troubleshooting Guide

Page 31: Process Mapping - SectionProcess+Mappin… · • Process mapping is a – simple & visual ... – Understand how your process map will help ... • Data layered on our process map

Spaghetti Diagrams

Page 32: Process Mapping - SectionProcess+Mappin… · • Process mapping is a – simple & visual ... – Understand how your process map will help ... • Data layered on our process map

Work Instructions & Audits

Page 33: Process Mapping - SectionProcess+Mappin… · • Process mapping is a – simple & visual ... – Understand how your process map will help ... • Data layered on our process map

Value Stream Maps

So why is the “Lean Guy”

waiting to talk about  Value Stream Maps until the end?

Page 34: Process Mapping - SectionProcess+Mappin… · • Process mapping is a – simple & visual ... – Understand how your process map will help ... • Data layered on our process map

The Value Stream Map

75 miles @ 65mph = 1hr 9min

Page 35: Process Mapping - SectionProcess+Mappin… · • Process mapping is a – simple & visual ... – Understand how your process map will help ... • Data layered on our process map

Process Option 1

100 miles estimated time 1hr 59min

Page 36: Process Mapping - SectionProcess+Mappin… · • Process mapping is a – simple & visual ... – Understand how your process map will help ... • Data layered on our process map

Process Option 2

82.8 miles Estimated Time 2hr 25min

Page 37: Process Mapping - SectionProcess+Mappin… · • Process mapping is a – simple & visual ... – Understand how your process map will help ... • Data layered on our process map

Common questions & pitfalls

Page 38: Process Mapping - SectionProcess+Mappin… · • Process mapping is a – simple & visual ... – Understand how your process map will help ... • Data layered on our process map

Common questions & pitfalls• You don’t need fancy software• Stay focused on the problem statement

– Use A3 whenever possible.• Remember the map is only the tool – it is not 

the end product

• It’s ok to be creative as long as you are  consistant

Page 39: Process Mapping - SectionProcess+Mappin… · • Process mapping is a – simple & visual ... – Understand how your process map will help ... • Data layered on our process map
Page 40: Process Mapping - SectionProcess+Mappin… · • Process mapping is a – simple & visual ... – Understand how your process map will help ... • Data layered on our process map

Thank you

Bob Wallner, CPIM

[email protected]

&

Open Networker look for me on