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Process mapping

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  • #46371

    Saidane
    Participant

    Hello everyone,
    In order to understand better the process mapping and all the types of flowcharts (swimlane, spaghetti diagram, as is…) I am requesting explanations, help, advice or/and some templates…
    Best Regards,
    Nizar

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    #153048

    qualitycolorado
    Participant

    Nizar,Have you tried the “Search” function in the upper right-hand corner of the iSixSigma site?
    Best regards,
    QualityColorado

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    #153057

    Allthingsidiot
    Participant

    QC
    Have  prepared  an  excellent PPT on PM,if  you  wish  I  can  share it  with  you ,as  you  are  very  cooperative ,

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    #153066

    G
    Participant

    Nizar,
    Try this link to an article in the ‘Top 25 Articles”, it has other links on the tools and templates you will need to complete your project.
     
    G~
    https://www.isixsigma.com/library/content/c020617a.asp

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    #153067

    Saidane
    Participant

    Hi,
    Thank you for your interest :) My project plan is based on this road map..so i’m trying to use it effectively.
    Best Regards
    Nizar

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    #153065

    Saidane
    Participant

    Hello,
    I will be very grateful thanks.
    QualityColorado, I have read all things in thiswebsit, but I wanna more detailed explanation with samples as it my first six sigma project :)
    Best regards,
    Nizar

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    #153070

    qualitycolorado
    Participant

    Nizar,Congratulations on your first Six Sigma process improvement project. A few questions:1. What is the aim (purpose or target) of your project?

    2. How do you plan to deploy flowcharting (and related flow chart analysis tools) to help you achieve that aim?
    I am hopeful that your Six Sigma training covered flowcharting in some detail — it is one of the most ferquently used Six Sigma tools.In addition to 1) your training and 2) the material that is readily available elsewhere on the iSixSigma site, here are some additional references that may be of assistance:1. Flowcharting basics
    http://www.robertluttman.com/flowcharts.html2. “Lean Six Sigma” open courseware from the Massachusetts Institute of Technology, aka MIT, (includes several modules related to flow charting):http://ocw.mit.edu/OcwWeb/Engineering-Systems-Division/ESD-60Summer-2004/CourseHome/index.htm
    Keep us apprised of progress on your first Six Sigma project.
    Best regards,
    QualityColorado

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    #153102

    Saidane
    Participant

    Hello QualityColorado,
    My project is about reducing delivery delays in a garment manufacturer using DMAIC methodology, that includes improving the production process and reducing delays in the supply chain…
    Flowcharting the process has for objectives: to make the process more clear for the personnel and managers, and to determine key measures(X’s and Y’s)…
    I didn’t have any training on Six Sigma, this is my own effort, and that’s make it a bit difficult for me :) so any help and support will be very appreciated. I will keep you update of the progress on the project.
    Best Regards,
    Nizar

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    #153104

    Madhusudan kshetri
    Participant

    Hey Nizar,
    It’s interesting to learn about your personal effort to apply Six Sigma methodology, DMAIC in your business. Your keen interests on is great!
    I am Madhusudan kshetri from Six Sigma IQ in Dubai. Might there be value for you if you can contact us vie email sending your Comapny’s contact details at [email protected]
    Thank you.
    Madhusudan

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    #153116

    Allthingsidiot
    Participant

    Dear  Nizar  (to  be  honest)  this  is  really  a  complete  nonsense?Please, you  are  spoiling  the  image  of  SS by  doing  so?Start  to  learn  some  basic  knowledge  and  tools  before  jumping  to  performing  such a  project using  a  general  basic  tool  like  PM??You are  becoming Like  a  person  who  jumps  to ” brain-sugery”  without  any  knowledge  or  experience??Best  Luck  for  your expected  hard  efforts?

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    #153119

    SS
    Member

    Nizar: what project are you doing and how is it going?
    How are you deploying and documenting all the tools you are using?
    SS.

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    #153120

    Saidane
    Participant

    Dear Allthingsidiot,
    Thank you for your comments. I think that Six Sigma is not only allowed for experts, we can try and learn… and everyone begin with Zero point and has the right to perform his skills in the way he desire! I am not going to spoil the image of SS, SS doesn’t depend on my succes or failure…I think you might wish me good luck, it is better for a beginner..and who knows? the beginner…can do sth anyway!
    Thank you for your interest again:)
    Best Regards,
    Nizar

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    #153115

    Allthingsidiot
    Participant

    Nizar
    It  is  really  difficult  to  believe  that  a  SS project  is based  only  on  this  simple basic  tool?It  should  be  rather  a  “white”  belt  Project??

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    #153121

    Saidane
    Participant

    Hello SS,
    My project is about reducing delivery delays in a garment manufacturer using DMAIC methodology, that includes improving the production process and reducing delays in the supply chain…
    I developed the project charter, identified CTQ’s, draw the SIPOC diagram…in summary Defined the project. I begin now to mp the process and use flowcharting to identify key measurements and improvement opportunities…
    I didn’t have any training on Six Sigma, this is my own effort, and that’s make it a bit difficult for me :) so any help and support will be very appreciated.
    Best Regards,
    Nizar

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    #153123

    SS
    Member

    Nizar: Ok I got it.
    I am no great expert in Six Sigma but I have fairly good understanding of process and production. More so familiar with the tools and techniques. I will try to help and support you as much as I can.
    Are you on the msn or yahoo chat? I am online.
    Thereonwards I can support you with the tools and techniques once we identified the right tools at each of the DMAIC stages.
    If you are on line let me have your msn or yahoo mail id.
    SS.
     

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    #153129

    qualitycolorado
    Participant

    Nizar,
    I did not realize that you had no Six Sigma training.  I applaud you for your willingness and courage to forge forward with an improvement project.
    Please be aware that it may be difficult to do this without training and without someone on-site with you to mentor you through your effort. So, keep your spirits high!
    Process Flowcharting is one key tool in Six Sigma efforts (but, it is only one).  It provides you glimpse into the “Process Door” of your effort.  This link has some information (and an example) for flowcharting as well as tips for analyzing the flowchart:
    http://www.montana.edu/wwwtreas/pfc.htm
     
    The other key “door” is the “Data Door”. Typically, it is useful to “open” both the Process Door and the Data Door in your Six Sigma effort.
    What kind of data are you looking into while you are flowcharting?   Are you reviewing data about the delays (how long; what kind of delays; most-frequently occuring delays; areas where the delays occur, etc.)?  You mentioned your project  is targeting reducing delivery delays in a garment manufacturer.  Do you have a specific target (such as “reduce delays by XX%)?
     
    Best regards,
    QualityColorado   
     
     

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    #153124

    Saidane
    Participant

    Hi SS,
    First, thank you for your interest and support. I am online and this is my msn ID: [email protected] or in skype: nizar-2007.
    Thank you again :)
    Best Regards,
    Nizar

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    #153139

    SH
    Member

    This is a prime example, where online training would benefit and be useful for someone like Nizar!

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    #153135

    accrington
    Participant

    Hi Nizar
    You can safely ignore anything that this pillock says to you. He still regularly asks this forum to do his Villanova U. homework for him.
    What you are doing to try to make the process visible, and identify key X’s and Y’s is fine, particularly if you are involving the rest of your organisation in making the process visible. A simple, but powerful tool like PM will also demonstrate to the rest of you organisation that continuous improvement is not difficult, can be done by everyone, and is not just the preserve of a special ‘caste’ with 16 weeks on – line training in arcane mumbo – jumbo about normal distributions, 1.5 sigma shifts and belts of various hues.
    Let us know how get on. From little acorns….

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    #153140

    Saidane
    Participant

    QualityColorado,
    I developed a high-level Swimlane flowchart, so I can see the material flows. Now, I am going to detail subprocesses…in order to define key meaurements and the process “problems” (location, unit, impact…). I wanna have a look at a flowchart template just to have an idea about how a process is typically mapped to help ensure best comprehension of the process and improvement opportunities.
    Concerning Data, they are related to delays in the Supply Chain and into the process itself, e.g : delays in supplying materials(both external and internal), delays due to the non managed production capacity or to non efficiennt schudeling policy, delays due to internal communication or data flows interuptions, low productivity…etc..
    As project goals: Reducing Delays by 80% and improving production process.
    I am really facing some difficulties, but I am learning and it’s a great opporunity to deploy Six Sigma and DMIC methodology, and I am lucky to be supported by many like you, SS, Mr. Adam and others..so many thanks for you and for anyone who was interested:)…it is a nice, strong, and amazing experience. Just to let you know, It is the first Six Sigma project to be deployed in the Apparel industry in Tunisia and even my professors didn’t get an idea of what does it mean Six Sigma, not because of weak but because our Engineering schools are more oriented to the technical and scientific issues…
    I am very grateful for your generous help,
    Nizar

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    #153142

    howe
    Participant

    Can someone give me advice on where to purchase the rolls of paper that is used to process map? Often called a Brown Paper exercise.
    I am having a difficult time finding a supplier.
    Thanks.
     

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    #153143

    Saidane
    Participant

    Hi accrington,
    Thank you for your encouragement:) I am continiously involving top managrs and all personnel..and trying to bring a cultural change by meetings, improving communication,etc… this is an opportunity to learn and to improve..
    Regards,
    Nizar

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    #153144

    qualitycolorado
    Participant

    Mike,
     
    Regarding the Brown Paper exercise — the rolls of wide paper (whether they are really brown or white or some other color) are often referred to as “butcher paper”, since they used to be used by butcher shops to wrap meat.   They are also called “kraft paper”
     
    Some on-line sources like Office Max have them — here is the reference number from OfficeMax for kraft paper rolls that are several hundred feet long, in various widths (1 foot, 2 feet, 3 feet, 4 feet, etc):
     
    http://www.officemax.com/max/solutions/product/prodBlock.jsp?BV_UseBVCookie=yes&prodBlockOID=536992435&expansionOID=-536892117
     
    I am sure that other office-supply stores, and perhaps craft supply stores (like “Michaels” and similar stores), will have them, too.
    … hope this is helpful ….
     
    Best regards,
    QualityColorado
     

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    #153146

    qualitycolorado
    Participant

    SH,   Agreed.  In lieu of not having training, some on-line sources would help fill some gaps (but cannot fill them all).  I have always been a major proponent of self-paced learning, including the materials available on-line; but I also recognize that it has its limits in many situations.
     
    Nazir,
     
    There is a considerable amount of information that is available for free from some on-line “open courseware” — here is another one that may be useful to you, regarding “Lean”:
    http://ocw.mit.edu/OcwWeb/Aeronautics-and-Astronautics/16-852JFall-2005/LectureNotes/index.htm
     
    There is a lot of good material there.  Especially, please look at the “lecture notes” about “Value Stream Mapping and Analysis” — this may help you with your flowcharting (and the related analysis about “value add” and “non-value-add” steps in the flow):
    http://ocw.mit.edu/NR/rdonlyres/Aeronautics-and-Astronautics/16-852JFall-2005/5C0D3B82-5724-4F0A-BE57-9187539F9B7E/0/2_lean_fundament.pdf
     
    … let us know if this is helpful to your efforts ….
     
    Best regards,
    QualityColorado

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    #153155

    Allthingsidiot
    Participant

    accrington
    Finally  you  have “announced” your  complete  ignorance in  SS (What  a  shame).By  giving  Nizar  such  a  “stupid” advice.It  is  well  known  that  the  flow   chart (PM or  even  the  SIPOC)  is  mainly  used  in  the  initial  Define  stage,and  you  can’t  expect  a  miracle  from  using  this  simple  tool?May  be  you  don’t  even  know  that  for  completing  a  SS  Project  we  have  to  go  through  some  other important 4   stages (MAIC),where   we  expect  ” strong” tools  to  be  used  to  achieve the desired  results,may  be  you  havn’t  heard  about  such other simple  tools  like;Histogram,Pareto,c&e D..Now  I’m sure  that  you  don’t  know  how  to  use  such  more  advanced  tools  like:Regreeion Analysis,Hypotheis  Testing,,ANOVA,T-Test,FMEA,DOE,and  the  advanced  Control  Charts.So  instead  of  missguiding  Nizar .I  would  advise  you  to  upgrade  your  SS Knowledge (even  your  basic  knowledge),secondly  when  I  have  asked  (such  a  stupid  person)  to solve  my home-work?I  really  enjoy  receiving  smart  comments from clever  people  and  you  may  recognize  that.Best  Wishes 

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    #153157

    Allthingsidiot
    Participant

    Dear Nizar
    Don’t  believe  him  ,as  he  is  giving  you  wrong  advice?Follow the  DMAIC  stages  and  try  to  apply relevant  simple  tools  for  each  phase,don’t  jump  to conclusions:
    For Define  stage :use Project  charter,flowchart ,SIPOC D.,VOC
    For Measure  phase :data  collection plan,,Measurement  system  analysis,process  sigma  calculation..
    For Analyse  phase:Histogram,,Pareto,Run chart,scatter plot,5Whys,Process  Mapping,
    For Improve  stage:Mistake profing,house  of  quality,,FMEA…
    For  Control  phase:Again  process  sigma  calculation (to  identify  the improvement),control  charts (variable  and  attribute depending  on  your  status),cost  saving  calculation ,control  plan.
    This  brief outline  should  help  you  to  perform  a  successful  project,step  by  step.Have to  initiate  first  a  brainstorming session,involving  all  stakeholders to  guarantee  top  management  support.Perform  a  time  schedule with  assinments  and  dates for  performing  the  assignments.Do not do everything  by  yourself.finally  don’t  rely  only  on  the  Process  Mapping  as  the  sole  tool  for  performing  a  project.
    Hope  to  receive  your  positive  feedback,and  good  luck 

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    #153160

    accrington
    Participant

    How many real projects have you worked on?
    How many years experience in the application of CI/ statistical methods do you have?
    How much money have you saved your organisation?
    What response do you get from your peers, guys on the shop – floor, people in procurement, etc., when you start spouting this drivel?
    Does anyone in your organisation think that you’re anything but a prat?
    Nizar, sensibly, is using a simple, powerful, and visual method to define his process and its associated metrics, to engage other people as a team and get their buy – in. This is an ideal way for him to start to get people interested, and move on to improve the process, using whatever methods are appropriate. Thsi is what he asking people in this forum for help with.
    If  he starts spouting a smart – ass shopping list of techniques like the one that you have just posted to his fellow workers, he’ll marginalise himself.
    There is a real world outside your Six Sigma CD and simulated case studies, which hardly ever works out like the text – book says it should
     

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    #153168

    Steven Bonacorsi
    Member

    Hello Nizar,
    I can help you with templates, Q&A, and some book references on various process maps, including: SIPOC, Swimlane, Top-down, AS-IS, Future-State, VSM, Org charts, Speghetti Diagrams, organizational layout, core value chains, theoretical best maps, Gannt charts, critical path analysis, relationship maps, network diagrams, use cases, and on and on… send me a message at [email protected] and i’ll send you some material, tools and templates. Best Regards, Steven Bonacorsi

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    #153166

    Jim Shelor
    Participant

    Nizar,
    You are proceeding with your project in exactly the right way.  A map of the process is an indespensible step that I often see Black Belts fail to employ.
    You are also in the right place to get help in walking through the project.
    Once you have your process map, we can help you with how to gather the data that will determine how long each step takes (min, max, and most likely) and then identify the critical path.
    Once the critical path has been identified, we can help you determine which steps in the critical path to start your improvements and you are on your way.
    The distinct advantage of the process map is determining the critical path and then the steps in the critical path to improve to get the most improvement in the overall process.
    As your improvements take effect, the critical path will change and the next step to improve will become apparent.  Sometimes, you will be able to perform more several improvements in parallel.
    Eventually, you will improve the process as much as it can be.
    I started out the way you are.  I had a large project to perform and had no Six Sigma training.  So I picked up a book and started reading and doing the things that seemed best at the time.  I eventually finished the project, with some good results,but it took longer than it should have, and I am sure the results could have been better. 
    You are starting out better than I did because I did not have the good sense to avail myself of the help available on forums like this.
    Go get them tiger, keep charging.

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    #153177

    qualitycolorado
    Participant

    Nizar,
    I concur with Jim Shelor — you are approaching this well!  It sounds like this is a ground-breaking effort for you as well as the apparel industry in Tunisia, and I know that everyone on the Discussion Forum wants this to be a success for you. 
    Regarding your Swimlane (functional) flowchart … you wanted to proceed with comparing yours to some templates.  I have not seen any flowcharts for your specific industry and situation, but here are a few that may give you a better idea regarding variations in how they are constructed (to help you in your comparison efforts):
    http://www.cps.gov.uk/publications/finance/process_mapping.html
    http://www.uwec.edu/Sampsow/307/2005c/PowerPoints/Workshops/FlowCharts-002.ppt
    http://www.publications.doh.gov.uk/ipu/socialcare/demonstrator/TRAINING/mapss_process_mapping_course.ppt
    I don’t know what tools you have to help you with flowcharting — hopefully MS Visio or something like it; if you just have MS Excel, here are some instructions for making a flowchart in Excel:
    http://www.breezetree.com/articles/how-to-flow-chart-in-excel.htm
     
    Concerning Data and your goal to reduce delays by 80% and improving production process … this is a very aggressive goal, particularly since this is your first Project.  I applaud you for setting an aggressive goal. An aggressive goal also means that you will need to start doing some in-depth Data Analysis and pair that up with your Process Analysis.  Have you been able to trend your data? Does any of the data lend itself to preparing a Pareto Chart and conducing a pareto analysis (an “80/20” analysis)?
     
    Best regards,
    QualityColorado 
     

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    #153206

    Saidane
    Participant

    Hello,
    Thank you for your interest. I am sure that the process mapping is an important step in the project, especially in the apparel industry. In fact, in such complicated industry, charactirized by labor intensive, frequently changing models in assembly lines, short runs…most of process owners do not have a clear idea about their processes and they couldn’t see interactions between processes.
    This project is about learning, then improving knwoledge…
    Best Regards and thanks again :),
    Nizar

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    #153211

    Saidane
    Participant

    Good Morning QualityColorado,
    Thank you for all your generous support, it touches me alot. All links you sent me were very useful and I am reading them carefully…it’s an opportunity to self evaluation, to learn, to improve, to deploy, to success and to fail…I really look further then this step. After this project, I am planning to get a training in Lean,Six Sigma  in Europ or in the US.
    Concerning tools I have Ms Visio for flowcharting and Statistica for Data analysis, I developed a detailed project plan using Ms Project Pro.
    I agree with you, this is an agressive and ambicious goal as a beginner, but I am sure I can sucees, not only by deploying DMAIC but by driving a cultural change in the company: learning people how to analyse, how to improve, how to control and the best method to communicate…
    Next steps: Detailing the process flowchart, identifying key measurements(and their units), developing a data collection plan, get involved process owners, and start measure for 1 month… then Statistica will allow me to better process analysis.
    I am very grateful fo your help,
    Best Regards,
    Nizar

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    #153207

    Saidane
    Participant

    Good Morning Jim,
    I agreee with you, the process mapping is a powerful visual tool for process improvements and for communicating with process owners.
    I am plannig the process flowchart to : understand more the process, make it clear for managers, determine where process problems are located…and after all to learn :)
    Thank you  for your encouragements, and I will keep you apdate about project progress. I liked this sentence; it push me hard :”Go get them tiger, keep charging.”
    Best Regards,
    Nizar
     

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    #153255

    Lebowski
    Participant

    Nizar,
    Try something out of the box on this one since you have read everything on this website about Process Mapping.
    Try doing one. I don’t have any data on this but I would be willing to wager that a mistake on a process map isn’t a capital offense no matter where you are.
    It is a good thing you don’t have to do something really complicated like a histogram.
    Lebowski

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    #171356

    Engine Lady
    Participant

    Please send to me ..I need those slides for my work

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    #176298

    Hans Kuendig
    Participant

    Hi Nizar,
    I saw that you had developed a high level swimlane chart. Would you be able to share that with me? I am looking for an example because someone had told me about swimlanes and I don’t know what that refers to. Unfortunately, the example they have on the six sigma site is a Powerpoint 95 example that my up to date version cannot open.
    Hans

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    #176301

    Mikel
    Member

    Good boy.Now roll over and play dead.

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    #176302

    Mikel
    Member

    You can go to a variety of software sites and get free 30 day trails that
    cover this.Try Quality Companion.And for Robert S’s sake, I have no association with any provider of
    software or materials for sale.

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