6 Sigma Process Mapping

Six Sigma
Process Mapping
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Six Sigma Methodology and Roadmap for Common Tool Usage
Define
Measure
Analyze
Improve
Control
Project Charter Process Map Rolled Throughput Yield Quality Function Deployment Value Stream Map Cause & Effect Matrix Potential Failure Mode and Effect Analysis Data Collection & Sampling Measurement System Analysis Statistical Process Control Capability Study Components of Variation Hypothesis Testing/Confidence Intervals Design of Experiments Control Plan Celebrate
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Copyright SKF,2002, All Rights Reserved
Six Sigma Mining for Key Process Input Variables xs

Define Measure
All Xs Found in Process Map 1st Hit List
Reduced in Cause & Effect Analysis
Analyze
Improve
Screened List
Filtered in Failure Modes & Effects Analysis Found Critical Xs
Validated with DOE, Hypothesis Tests, Confidence Intervals
Control
Controlling Critical Xs
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Objectives

Provide overview of types of maps
Link Process Mapping with process improvement Explain how to create a process map Show examples Do an exercise
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Types of Maps
Process Map
One of the first steps in the Six Sigma
process Critical for process improvement to reduce/remove variation
Project Finder
Value Stream Map
Project selection
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Project Work Common Characteristics

More questions than answers Dynamic Parallel activities, rather than sequenced Communication necessary Documentation necessary May be difficult to know where to start You may not be the expert
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Y = f(x 1 , x 2 , x 3 ,..., x k )
These are some questions we will need to answer!
Remember, we are trying to learn
How will we identify the xs?
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A Process Map Is
Used to begin EVERY project!
A graphical tool to illustrate the way a process is currently working

Dynamic A team effort done by walking the process A tool to GAIN PROCESS KNOWLEDGE!
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Uses of Process Maps

Learn about a process through questioning Data collection Determine details of a project What factors to investigate or omit Where and how to sample Identify process owners Evaluate ALL types of processes Management, Administrative, Financial, Service, Design, Manufacturing
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Process Maps Describe

Major activities/tasks Value added and non-value added steps Process boundaries Inputs (xs) Outputs (ys or Ys) being measured or in need of measurement systems Where data is (or should be) collected Current operating parameters
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Process Map = Process Flow Chart
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Process Map

(Process) Flow Chart

Does not show inputs and outputs Shows the flow of the process Shows decisions and alternate pathways May not show the process steps as-is. Rather, it may reflect the process as it should be (for your ISO procedure, for example) Helps streamline flow Does not focus on reducing variation
Shows inputs and outputs Shows the steps of the flow of the process May or may not show decisions Shows the steps of how the process actually works Helps streamline flow Helps make process improvements by understanding, and controlling inputs to eliminate variation
Process Maps and Flow Charts

Value Stream Flow charts Reduce Waste
Process maps Drive reduction in variation
Our primary focus will be on Process Mapping

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Process Mapping Terms
Input variables may influence process steps xs or factors Output variables or customer requirements
Big Ys when referring to final output Little ys when referring to measurements
taken upstream
Y f (x1 , x 2 ,..., x k )
Understand and control the xs to control the Ys
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Process Mapping Steps

1. Identify the process and its primary inputs and outputs (50,000 ft. view) 2. Identify all steps in the process (5,000 ft. view) 3. List output variables at each step
4. List input variables (and operating parameters) at each step

5. Classify each input variable as Controllable, Noise or a Standard operating procedure A Belt should have the Process Map complete within the first meeting with the team
Step 1: (High Level) Identify the Process and Inputs/Outputs Identify external inputs
Raw materials Energy requirements Incoming information
Identify end customer requirements

(outputs, or Ys)
on-time correct quantity perfect quality CTQ

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Examples - Step 1
Manufacturing
Inputs
Stamping C Prep C Solvent C Nozzle S .
Outputs
Molding
Coverage Thickness Hardness Color Leak Test .
Non- Manufacturing
Inputs
EDI FAX Email . .
Outputs
Order Entry
Price & availability Confirmation of order Promise date Order number . .
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Step 2: Identify All Steps in the Process
Identify the process flow steps Tips Try to show in 3 8 Steps Start with the end and the beginning. Then, fill in the middle. Include all value-added and non value-added steps Process steps, inspection/test, rework, scrap points WALK THE PROCESS! A Process Map isnt done on the computer! While you walk the process you will also be identifying xs and ys (next steps)
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Manufacturing Example - Step 2
534818-60 Process Map

Process Steps Design Supplier Phosphate Cem ent Extrusion
Process Steps
Mold Press
Trim
CNC Turn
SKF India
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Non-Manufacturing Example - Step 2

STEP 1 Answer Phone / Greet Customer STEP 5 Complete order worksheet
STEP 2 Determine Part Number / price / need date
STEP 6 Input order on computer
STEP 3 Get PO #
STEP 7 Verify order info fax to customer / transmit to plant
STEP 4 Identify ship to address, method of shipment
STEP 8 Verify plant receipt of order
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Step 3: List Output Variables
Include all output variables (the ys).
Defines the scope and objectives of the process Indicates where measurements are taken during the process Labels and differentiates between what is and what is not currently measured Defines In-Process parameters (ys) which are measured UPSTREAM from the final output (Y)
Tip: May be easier to list the outputs and inputs (Steps 3 and 4) by step before moving on to the next step
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Manufacturing Example - Step 3

Process Steps Design Supplier Phosphate Cem ent Extrusion
Outputs
Manufacturability
Good stam pings
Even application Good bond
Even application Correct cem ent
Correct w eight Correct appearance
Process Steps Outputs
Mold Press
Trim
CNC Turn
Runout in tolerance
Clean lip No tears
Runout in tolerance
SKF India
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Non-Manufacturing Example - Step 3

OUTPUTS STEP 1 Answer Phone / Greet Customer Prompt answer Live body
STEP 2 Determine Part Number / price / need date
Customer info Pricing Availability
Customer PO
STEP 3 Get PO #
STEP 4 Identify ship to address, method of shipment
Ship to address Method of shipment
SKF India
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Non-Manufacturing Example - Step 3 (Continued)

OUTPUTS STEP 5 Complete order worksheet Complete order info from customer
Order in computer
STEP 6 Input order on computer
All fields completed Promise date Printed confirmation
Correct info Confirmation to customer Order sent to plant
STEP 8 Verify plant receipt of order
Completed order entry
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Step 4: List Input Variables
List all input variables (xs or factors)
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Step 5 - Classify Input Variables
Classify the input variables
CONTROLLABLE INPUTS (C) NOISE INPUTS (N) STANDARD OPERATING

PROCEDURES (S)
NOTE: Further experimentation confirms the estimated classification! THESE CAN CHANGE!
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CONTROLLABLE INPUT variables (C)
Input variables (xs or factors) that can be changed to see the effect on output variables. These are sometimes called Independent Variables xs that are critical (Key Process Input Variables) xs that have no effect
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NOISE (N) Inputs that impact the outputs but are: 1. Uncontrollable 2. Too costly to control 3. Preferably not controlled Example - An environmental variable such as humidity
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STANDARD OPERATING PROCEDURE (S)
Inputs that are defined by operating procedures that may be considered common sense activities
Examples: Training, Cleaning, Preventive Maintenance
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Process Map Example Steps 4&5

Inputs TBD by Engineers TBD w / Supplier Bath tem p C Contam ination N Tim e in bath C Micro or m acro C Viscosity C Part tem p C Gun position S Gun Pressure C Spray duration C Process Steps Design Supplier Phosphate Cem ent Prep w eight C Concentricity C Height C Diam eters C Parallelism C Extrusion
Outputs
Manufacturability
Good stam pings
Even application Good bond
Even application Correct cem ent
Correct w eight Correct appearance
Inputs
Tem p C Tool design N bum ps C Pressure C Press parallelism C
Blade condition C RPM C
RPM C Blade condition C Jaw pressure C Misload by operator C
Correct press loading C Blade position C
Process Steps Outputs
Mold Press
Trim
CNC Turn
Runout in tolerance
Clean lip No tears
Runout in tolerance
SKF India
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Non-Manufacturing Example - Steps 4&5

INPUTS Order worksheet form C Customer supplied info N OUTPUTS STEP 5 Complete order worksheet Complete order info from customer
Order worksheet
C STEP 6 Input order on computer
Computer entry screens C Lead time info from mfrg. N
Order in computer All fields completed Promise date Printed confirmation
Printed confirmation C
sheet
Customer contact info N Confirmation procedure C
Correct info Confirmation to customer
Order sent to plant

Correct info in computer C Mfrg plant contact C STEP 8 Verify plant receipt of order Completed order entry
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Preparing the Process Map
Team Effort
Manufacturing engineers Line operators Line supervisors Maintenance technicians Brainstorming Operator manuals Engineering specifications Operator experience 6Ms
Possible Inputs to Mapping
Man, Machine (Equipment), Method (Procedures), Measurement, Materials, Mother Nature (Environment)
Keep it Simple Use Excel to allow copying into next tool (Cause and Effect matrix)
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Process Map Summary Process Mapping Provides Inputs to

Cause and Effect Matrix Potential Failure Mode Effect Analysis Control Plan Capability Studies Experimentation
Process Mapping helps us gain process knowledge!
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Your First Process Map Assignment

1. Study the flowchart of the Order Pickers Company 2. Create a Process Map individually
3. Compare and discuss your process map with partners
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The Order Pickers Company Flow Chart

RECEIVE Products Put Away Order Recv Pick
KEY:
Process Step
Inventory Rework Inspection/Test PACK/ SHIP
Consol idate
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SKF Example
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A Champion Calls You, the Six Sigma Green Belt, to Help the Team

She needs quality improved to land a big customer The customer is a national distributor Currently, the quality of our product line is only 2 Sigma The customer will buy all lines if each line meets quality levels Best-In-Class among competitors is 4 Sigma 6 Sigma capability on the CTQs will guarantee the business if able to ship-on-time Potential sales > $1,000,000 annually Scrap, rework, inspection costs exceed $250,000 annually The product family includes several molded products. One product line quality is world-class already and exceeds the expectations of this potential customer
Process Mapping Exercise 2

View the process as a team, one step at a time Observe the operator demonstrating his/her operation based on the written procedures at the station Ask questions of the operator to gain process knowledge about the inputs and outputs at the given step You have 5 minutes to view and question the entire process. After viewing/questioning the process, return with the team to the room to begin constructing the process map and answering Part II of the assignment.
FOCUS ON THE PROCESS, NOT THE PEOPLE!
Exercise to Apply Learning
Observe the factory with your team Create a Process Map Be sure to include all elements of
good Process Maps Draw on flipchart Presentations and Advice
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Assignment (Part II)

Describe the similarities and differences between Process Mapping and Flowcharting If the labeling of the inputs is correct, what behaviors and disciplines will be required of the operators? of the line supervision? of the senior management? Who should prepare, complete and assess the maps? What are you looking for? How and when should maps be updated?
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Review Questions - True or False?
Use YES/NO Cards

1. For constructing a process map, inputs should be
determined while walking and questioning the process with the team 2. Outputs listed on your process map are always measured 3. Process inputs are classified as Controllable or Noise or SOP 4. A process map should reflect the best way a process should operate 5. To make an accurate process map, it is best to do it alone so that you are not distracted by others 6. It is OK for a Belt to draft a Map for the Team to start from 7. Once a process map is constructed, it is never changed
Process Map Questions to Verify Quality of Map

Does it cover the project scope? Who helped develop the map? Did I get the operators input? Does it reflect current state or the desired process? Are all non value-added steps included? Are all inputs and outputs listed? Were any quick-hits found from this effort? What process steps does the team feel can be eliminated? What characterizes controlled and noise variables? What measurements are taken within the process? What measurements SHOULD be taken throughout the process? Did you and your team walk the process? How often? What is the next step and what is the timeline? Is there a lot of waste to warrant a Value Stream Map first?
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Update Tool Knowledge Histogram
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6 Sigma Process Mapping

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6 Sigma Process Mapping

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Six Sigma

Six Sigma Methodology and Roadmap for Common Tool Usage

Copyright SKF,2002, All Rights Reserved

Six Sigma Mining for Key Process Input Variables xs

Reduced in Cause & Effect Analysis

Filtered in Failure Modes & Effects Analysis Found Critical Xs

Validated with DOE, Hypothesis Tests, Confidence Intervals

Copyright SKF,2002, All Rights Reserved

Copyright SKF,2002, All Rights Reserved

Value Stream Map

Copyright SKF,2002, All Rights Reserved

Project Work Common Characteristics

Copyright SKF,2002, All Rights Reserved

Copyright SKF,2002, All Rights Reserved

Used to begin EVERY project!

A graphical tool to illustrate the way a process is currently working

Copyright SKF,2002, All Rights Reserved

Uses of Process Maps

Copyright SKF,2002, All Rights Reserved

Process Maps Describe

Copyright SKF,2002, All Rights Reserved

Process Map = Process Flow Chart

Copyright SKF,2002, All Rights Reserved

(Process) Flow Chart

Process Maps and Flow Charts

Process maps Drive reduction in variation

Our primary focus will be on Process Mapping

Copyright SKF,2002, All Rights Reserved

Process Mapping Terms

Copyright SKF,2002, All Rights Reserved

Process Mapping Steps

4. List input variables (and operating parameters) at each step

Identify end customer requirements

on-time correct quantity perfect quality CTQ

Copyright SKF,2002, All Rights Reserved

Coverage Thickness Hardness Color Leak Test .

Price & availability Confirmation of order Promise date Order number . .

Copyright SKF,2002, All Rights Reserved

Step 2: Identify All Steps in the Process

Copyright SKF,2002, All Rights Reserved

Manufacturing Example - Step 2

534818-60 Process Map

Copyright SKF,2002, All Rights Reserved

Non-Manufacturing Example - Step 2

STEP 2 Determine Part Number / price / need date

STEP 6 Input order on computer

STEP 7 Verify order info fax to customer / transmit to plant

STEP 4 Identify ship to address, method of shipment

STEP 8 Verify plant receipt of order

Copyright SKF,2002, All Rights Reserved

Step 3: List Output Variables

Include all output variables (the ys).

Copyright SKF,2002, All Rights Reserved

Manufacturing Example - Step 3

Good stam pings

Even application Good bond

Even application Correct cem ent

Correct w eight Correct appearance

Process Steps Outputs

Clean lip No tears

Copyright SKF,2002, All Rights Reserved

Non-Manufacturing Example - Step 3

STEP 2 Determine Part Number / price / need date