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| Drawing a process picture answers questions like: |
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i. Where does the process start?
ii. Where does it end?
iii. Who is involved?
iv. What are the process steps?
v. What are the process improvements?
vi. What methods are used? |
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| All inputs to the process are called |
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| the processing step that transforms the X into Y the Y is a function of X |
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| The value stream (supply chain)are processes with steps that create |
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| tangible flow of material as well as the intangible flow of information and services |
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| Supplier->Input->Processing->Output->Customer |
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| What's the next step after value stream mapping? |
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| What does mapping the process do? |
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| Captures the operational knowledge of the process |
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| Identifies Suppliers, Inputs, Outputs, and Customers |
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| High level starting point - used in most DMAIC projects |
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| Shows decision points and If/Then logic |
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| Displays procedures and logic of process |
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| Deployment Flow Chart (Swim-lane chart) features |
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| Identifies functional responsibilities |
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| Deployment Flow Chart (Swim-lane chart)comments |
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| Communicates who does what |
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| Value-added flow chart features |
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| Separates Value-Added from Non-Value-Added operations. |
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| Value-added flow chart comments |
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| Identifies waste of many types. Stratifies time |
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| Spaghetti diagram features |
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| Shows physical flow of material and/or information. |
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| Spaghetti diagram comments |
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| Illustrates physical complexity, distance traveled, cycle time |
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| Identifies physical flow of materials and information. Quantifies inventory levels, process characteristics and control mechanisms. |
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| Value stream map comments |
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| Detailed map for lean improvement projects and Kaizen events. |
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| Focused on systemic cause and effect - shows reinforcing and balancing forces along with unintended consequences. |
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| Examines behaviors behind process performance - non-linear. |
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| -High level representation of a process or value stream |
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| Process maps are typically developed for what 2 reasons? |
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1. Identify waste and prioritize lean six sigma projects
2. Understand relationships between Xs and Ys |
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| What are some forms of waste? |
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-Defects or errors (result in scrap, rework or customer dissatisfaction)
-Unproductive movements
-Excess inventory
-Unnecessary time delays
-Wasted energy
-Unwanted products |
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| What is the first step in developing a SIPOC process flow chart |
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Gather team
Walk the process
Take notes |
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| What do process flow charts provide? |
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| A visual representation of the detailed steps in a process |
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| When are process flow charts useful? |
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| To represent procedures and decision-making routines |
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| What are benefits of flow charts? |
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-Give everyone a clear understanding of the process
-Highlights decision points
-Identify non-value added operations
-Facilitates teamwork
-Keeps everyone on the same page |
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| What is a spaghetti diagram? |
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| Diagram to identify the physical flow of material or information |
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| Two types of spaghetti diagrams |
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Movement of material
Movement of information |
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| What does the movement of material look at? |
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| Physical movement and highlights long travel routes and queue times |
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| What does movement of information look at? |
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| Number of times info is handled or manipulated |
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Customer demand
units required per period of time |
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| time elapsed between each unit demanded (inverse of rate) |
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-pace of customer demand
-cycle time
-the time to produce one unit if production is matched to customer demand |
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| How is takt time calculated? |
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| Total available process time/total quantity required |
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| Complete sequence of activities an organization performs in order to produce and delivers its end product or service |
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| Graphical representation of the series of activities the organization follows in producing and delivering end product |
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| what are the 2 main steps in value stream mapping? |
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1. map the current (current state)value stream
2. map the desired (future state) value stream |
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| What are the 5 steps to value stream mapping? |
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1. Prepare to map the current state
2. Map the current state
3. Identify lean metrics
4. Map the future state
5. Identify and plan kaizen events |
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