Process Mapping Process Mapping Lean Temple What is

Process Mapping

Process Mapping Lean Temple

What is Process Mapping § Dan Jones and Jim Womack define Value Streams as “the simple process of directly observing the flows of information and materials as they now occur, summarising them visually, and then developing a future state with much better performance” § Pictures are worth thousand words!

Process Mapping Policy; a management system. A framework of direction and guidance for a Process Policy, Process and Procedures Process; a structured set of activities that transform a set of inputs into specified outputs that provide value to the customer Input; Sponsor Order Resource Plan Procedure; a description of how a particular step in the process is managed and operated Create Job Description Procedure Advertise for position Interview Select Procedure Output; Delivery

Process Mapping When a sponsor (customer) sets the requirement they see the overall output not the processes within. . HSEQ Design Finance / Procurement Engineering Processes operate across functional boundaries Delivery

Process Mapping Why generate a Process Map? § Process Mapping is an effective tool to visually represent a process. § Allow for the identification of bottlenecks, delays and waste. § It will reveal the complete process, rarely does a single construction worker know all the processes and people involved in the construction journey. § It will help you to look for opportunities for improvement by visualising the whole construction process and identifying points of inefficiency. § Stimulates problem solving ideas within the team § Gain an in-depth understanding of the project or process § Forms a basis for improvement and generates a ‘Future State’

Process Mapping Process mapping Symbols The symbols are used to define elements of work into categories that are easily interpreted by everyone. OPERATION The VA activities, part or product is changed. TRANSPORT Movement of parts or material. INSPECTION Checking for quality. DELAY A waiting period where storage location is NOT controlled. STORE A waiting period where storage location is controlled.

Process Mapping Process mapping Symbols Jam Stored in the Fridge Is it OK? Take to Breakfast Table Waiting for Toast Spread on Toast Return to Fridge Jam Stored in the Fridge

Process Mapping How to create a Process Map § The team needs to follow a service or process from beginning to end and draw a visual representation of every process / step. § Include information flow and format i. e. paper, electronically etc. § Transfer all steps onto Process Flow sheet to highlight concern processes / steps i. e. delays, unnecessary steps, duplication of effort, things that don’t make sense, use the 7 wastes. § Record the teams comments.

Process Mapping How to create a Process Map § Map the process in order to understand the current process flow. The map exposes VA, Non VA and waste. § This activity can be done in a classroom environment but ideally should be done at the workplace. § Ask at each step what happens next.

Process Mapping

Process Mapping Waste Opportunities…. § Producing defective parts § Passing on defective parts § Not communicating improvements § Overproduction § Inventories § Motion § High Non-value ratio § Transportation § Waiting § Counting § Inspection after the fact § § § § Facility layout Excessive setup times Incapable process Maintenance Work method Training (or lack of) Production planning/scheduling § Lack of workplace organization § Supplier quality/reliability § Lack of concern

Process Mapping Quantification § How many individual actions (steps) on the process are there, what is the total throughput time, and what is the throughput distance? § Critical question: How do we know whether a step and its completion time create value?

Process Mapping Techniques Flow Chart Flow Diagram SELL PRODUCTS Order MANAGE ORDERS Invoice Request CUSTOMER Invoice INVOICE ORDERS Payment Dispatch Request Good Parcel Replenishment Order FULFILMENT MANAGE STOCKS Replenishment Delivery

Process Mapping Techniques Team develop and analysis the Process Map

Process Mapping What questions should we ask when analysing the Map? § § § How many steps are there? Could some tasks be carried out by one person instead of several people? Is there any duplication of work? Are there any bottlenecks? How much error correction / rework is being carried out? What is the approximate time between each step? Which tasks help to achieve the purpose and which ones do not, can those that do not add value to process be removed? Are we doing the right things in the process? Are we doing things in the right order? Is the right/best person doing it? What information do we give to staff/contractors at what stage and is the information useful?

Questions