1.

18 Process Map
Six Sigma Black Belt and Green Belt
Week 1
2008-06-01

Process Mapping Objectives

Provide an understanding of process mapping.
Learn the importance of process maps.
Understand how to create process maps and how to classify/filter
inputs in the process steps.

Detailed
Detailedmapping
mappingcan
canbe
beused
usedand
andbe
beuseful
usefulfor
forANY
ANYprocess.
process.
Such
SuchMaps
Mapsare
arerequired
requiredfor
forevery
everySix
SixSigma
Sigmaproject.
project.
2008-06-01 SKF Group Slide 1

SKF (Group Six Sigma)

1.18 Process Map

SKF Six Sigma Roadmap

Six Sigma Methodology and Roadmap for Common Tool Usage

Define Measure Analyse Improve Control

Implement Quick Hits at Any Time with Validated Data

Project Charter
SIPOC
MSA & Baseline Study on Y(s)
Value Stream Map and Lean Tools
Process Map
Cause & Effect Study
Potential Failure Mode and Effects Analysis
.
Measurement Systems Analysis
Data Collection & Sampling
Statistical Process Behaviour
Capability Study
Quantitative X,Y Relationships
Statistical Validation
Control Plan
Celebrate

2008-06-01 SKF Group Slide 2

SKF (Group Six Sigma)

1.18 Process Map

What is a Process?

Inputs

Outputs

People

Transformation

Equipment

Products
Goods
Services

Materials
Supplies
Information

Y=f(X1, X2, X3, ..., Xn)

Consequences

AAprocess
processisisaaseries
seriesof
ofactivities
activitiesthat
thattransforms
transformsaaset
setof
ofinputs
inputsinto
intoaa
specific
specificset
setof
ofoutputs.
outputs.
2008-06-01 SKF Group Slide 3

SKF (Group Six Sigma)

1.18 Process Map

Process Map Benefits

A process map visually describes:

Major activities/tasks
Variables, and their settings, tolerances, specifications
Customer expectations
Bottlenecks
Rework sub-processes
Suppliers

Process Maps are working documents.

Process
Processmaps
mapsare
areaavisual
visualrepresentation
representationof:
of:

Y=f(X1, X2, X3, ..., Xn)

2008-06-01 SKF Group Slide 4

SKF (Group Six Sigma)

1.18 Process Map

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

2008-06-01 SKF Group Slide 5

SKF (Group Six Sigma)

1.18 Process Map

Process Map =/ Process Flow Chart

2008-06-01 SKF Group Slide 6

SKF (Group Six Sigma)

1.18 Process Map

Process Map

(Process) Flow Chart

Shows inputs and outputs

Does not show inputs and outputs

Shows the steps of the flow of the

Shows the flow of the process

process

Shows decisions and alternate

May or may not show decisions

pathways

Shows the steps of how the process May not show the process steps asactually works

is. Rather, it may reflect the process

Helps streamline flow

Helps make process improvements

as it should be (for your ISO

procedure, for example)

by understanding, and controlling

Helps streamline flow

inputs to eliminate variation

Does not focus on reducing

variation

2008-06-01 SKF Group Slide 7

SKF (Group Six Sigma)

1.18 Process Map

Process Maps and Flow Charts

Value Stream
Flow charts
reduce Waste

FE E

Process Maps
drive reduction
in Variation

Our primary focus will be on

Process Mapping
2008-06-01 SKF Group Slide 8

SKF (Group Six Sigma)

1.18 Process Map

Preparing the Process Map

Walk the process!
Team Effort:
Cross Functional
Process owners
Customers
Suppliers

Inputs to Mapping:
Brainstorming
Operator Manuals
Specifications
Process Owner Experience
6Ms: Man, Machine, Method,
Material, Measurement, Mother
Nature

2008-06-01 SKF Group Slide 9

SKF (Group Six Sigma)

1.18 Process Map

Process Mapping Steps

1. Identify the process and its primary inputs and outputs (SIPOC)
2. Identify all steps in the process: value-added and non value-added
3. List key output variables at each step (process and product)
4. List key input variables (and operating parameters) at each step
and classify each input variable as Controllable, Noise or a Standard
Operating Procedure
5. Add the operating specifications and process targets for the
controllable and critical inputs

55 Easy
Easy Steps
Steps
A Belt should have the Process Map complete within the first meeting with the team

2008-06-01 SKF Group Slide 10

SKF (Group Six Sigma)

1.18 Process Map

Step 1: List Inputs and Outputs

High-Level Map
Dept. 45
Valve Body
Machining

Inputs
Valve body blanks
Labour
Tooling
Schedule

Process Owner: __________

Customers: ______________
Suppliers: _______________

2008-06-01 SKF Group Slide 11

SKF (Group Six Sigma)

1.18 Process Map

Outputs
Finished valve bodies
Volume
Model mix

Step 2: Identify all steps in the Process

Include value-added steps

Valve Body Blanks

from Dept. 30

OK?

Broach
Splines

Truck Parts
to Rework Area

Face & CBore

the Cut-Off End

Truck Parts
to Next OP

Include non-value-added
steps

Drill Holes & Ream

Process Notch

Audit &
Sort Blanks on
Length & Diameter

Face, Bore & CBore

the Slotted End

AutoInspect
Sleeve CBores

Drill
Missing Holes

Induction Harden
Splines

Grind
Sleeve OD

OK?
N

AutoInspect
Press Force

Audit
for ID

OK?
N

OK?

Audit
for
Skirt ID

SKF (Group Six Sigma)

1.18 Process Map

Wash

Sort by
ID Grooves

Scrap

OK?

UnderSized?

Finish OD &
Wire Brush

No - Scrap
Rough
ID

N Scrap
Truck Parts
to Next OP

Diamond
Size ID

Scrap

Wash

2008-06-01 SKF Group Slide 12

Grind
OD

OK?

Vibratory
Deburr

Yes - Rework
Drill, Ream
& Press in Pin

Deburr CBore
on Sleeve End

Inspect
Sleeve Depth

Finish Skirt ID, Skirt

Face, Ring Groove
Face & Chamfer

Truck Parts
to Next OP

Wash

Scrap
Grind
Slot

Draw
Furnace

Press In
Sleeves
Sleeve Blanks
from Dept. 30

Audit
for
Missing Holes

Final
Inspection
(Visual)

100%
Inspection
of ID

OK?
N

Scrap

OK?
N

Scrap

Store for
Transfer to Dept. 88

Step 2: Identify all steps in the Process (contd)

Finish OD &
Wire Brush

Rough
ID

Audit
for ID

Portion of complete process map

2008-06-01 SKF Group Slide 13

SKF (Group Six Sigma)

1.18 Process Map

OK?
N
Scrap

Step 3: Show Key Outputs at each step

Outputs
Outputs
Finish ground part 51.26/51.21 mm
De-burred part

Finish OD &
Wire Brush

Rough
ID

Ground ID at 29.289/29.307 mm
Run-out to OD 0.006 mm
Taper, roundness, & straightness
of 0.001 mm

Audit
for ID

OK?
N
Scrap

Portion of complete process map

2008-06-01 SKF Group Slide 14

SKF (Group Six Sigma)

1.18 Process Map

Step 4: List Key Inputs and

classify Process Inputs
Outputs

Outputs

Finish ground part 51.26/51.21 mm

De-burred part

Ground ID at 29.289/29.307 mm
Run-out to OD 0.006 mm
Taper, roundness, & straightness
of 0.001 mm

Finish OD &
Wire Brush

Rough
ID

Inputs
S!- Dress grinder to size
S!- Tool change!
N Grinding wheel
N Wire brush
S- Preventative maintenance
C- Coolant level
C- Coolant temp
S!- Audit requirements

Key:
! - Critical
N - Noise
S - Standard Operating Procedure
C - Controllable
2008-06-01 SKF Group Slide 15

SKF (Group Six Sigma)

1.18 Process Map

Audit
for ID

OK?

N
Scrap

Inputs
S- Tool change
S- Preventative maintenance
S!- Audit requirements
Diameter
Taper
Concentricity

! Inputs in red (!) indicate proven

critical input parameters.

Process Input Variables (xs)

Controllable Inputs: Input Variables (xs) that can be changed to see
the effect on Process Output Variables (ys). Sometimes called knob
Variables.
Noise Inputs: Input variables that impact the ys but are
uncontrollable, difficult, or too costly to control. Example:
Environmental variables such as humidity, ambient temperature, etc.
Standard Operating Procedures: Procedures that describe how the
process is run and identify certain factors to monitor and maintain. A
standard procedure for running the process.
Critical Inputs: xs that the tools (FMEA, DOE, SPC,etc.) and
significant process knowledge have proven to have a major impact on
the the ys. Any of the types of inputs can be critical (controllable,
standard operating procedures or noise).

2008-06-01 SKF Group Slide 16

SKF (Group Six Sigma)

1.18 Process Map

Step 5: Add the Operating Specifications and

Process Targets
Outputs

Outputs

Finish ground part 51.26/51.21 mm

De-burred part

Ground ID at 29.289/29.307 mm
Run-out to OD 0.006 mm
Taper, roundness, & straightness
of 0.001 mm

Finish OD &
Wire Brush

Rough
ID

Audit
for ID

Inputs
S!- Dress grinder to size
S!- Tool change!
N Grinding wheel
N Wire brush
S- Preventative maintenance
C- Coolant level
C- Coolant temp
S!- Audit requirements

OK?

N
Scrap

Inputs
S- Tool change
S- Preventative maintenance
S!- Audit requirements
Diameter
Taper
Controllable/Critical
Concentricity
Input Parameter

Key:
! - Critical
N - Noise
S - Standard Operating Procedure
C - Controllable
2008-06-01 SKF Group Slide 17

SKF (Group Six Sigma)

1.18 Process Map

Coolant Level
Coolant Temp

Target
17 gal
84 F

Upper
spec
18 gal
86 F

Lower
spec
16 gal
82 F

Process Mapping drives

Continuous Improvement

1st Filtration

Die pump
to 2nd Filtration

Coating

Filtered
adhesive

Rehumidification
Lamination

Speed
Steam Pressure
Temp profile
Temperature
Air temp
Inert gas flow
Silicone
differential speed
Nozzle
coverage
Roll Pressure
velocities
die settings
Face Moisture
+ Oven settings
Back up roll
+ die settings
Good DRY coverage
Rolls of
Good wet coverage
Adhesive to
V.C.
good
Coatweight
die CR2
Ctwt distribution
product
Profile Measure
Moisture

Pressure
+ Filters

Pressure
+ Filters

Drying

FMEA
MSA
DOE
SPC
I&CIM Tools
Regressions

Process
ProcessMapping
Mappingisisthe
thefoundation
foundationfor
forcontinuous
continuousimprovement.
improvement.

2008-06-01 SKF Group Slide 18

SKF (Group Six Sigma)

1.18 Process Map

Team Exercise
For the exercise given by the Instructor, prepare a Process Map.
Things to keep in mind
What are the boundaries of your process? Where does it begin & end?
What is the big "Y"?
What are the process outputs desired at the end of each stage? How do
you know the step is complete?

What are the inputs to each step? Can they be characterised? Who are
the key players required?

Are there any specifications or operating parameters to be considered

and placed on the map?

What is the significance of adding these elements to the map?

Dont forget to update your TMAP and SIPOC !

2008-06-01 SKF Group Slide 19

SKF (Group Six Sigma)

1.18 Process Map

Catapult Exercise
You have been selected to serve on the Companys elite catapult
squad. Your mission is to optimise the catapult process so that we
can overcome our competition.
A successful catapult squad can place a projectile on target nearly
every time (they will miss just 3.4 times per million).
Good luck! The penalties for failure are severe!! (Remember, this is
the 11th century!).

2008-06-01 SKF Group Slide 20

SKF (Group Six Sigma)

1.18 Process Map

Process Mapping Exercise

Break out into groups as designated by the instructor.
Work with your breakout group to create a Map for the catapult
process, based on your observations from the video.
Assign roles (scribe, leader, timekeeper, process monitor, others if
needed). Select a spokesperson to debrief the class.
Meet back here in 30 minutes!

2008-06-01 SKF Group Slide 21

SKF (Group Six Sigma)

1.18 Process Map

Process Mapping Summary

All work is a process
The result of a process depends on the steps and the inputs
Y = f(X)

A process map is an illustration of Y = f(X)

There are five steps to generating a process map
Walk the process yourself
Update the Process Map every time that an input appears to be
critical

2008-06-01 SKF Group Slide 22

SKF (Group Six Sigma)

1.18 Process Map

Appendix

2008-06-01 SKF Group Slide 23

SKF (Group Six Sigma)

1.18 Process Map

SKF
Example

2008-06-01 SKF Group Slide 24

SKF (Group Six Sigma)

1.18 Process Map

Process Map Example

Paper Making

Paper Supercalendering

(UPM)
Inputs

C
C!
S
S
S
C
C
C

Packaging/Shipping

& Finishing (UPM)

Outputs

fiber type

uncalendered sheet

papermaking factors

basis weight

paper machine

caliper

SOP

caliper uniformity

operators

density

wet end additives

density uniformity

size press

moisture content

size coating

moisture content unif.

runnability properties
tear strength
tensile strength

(UPM)

Inputs

C!
C
C
C
C
C
S
S
C
C
N

supercalender factors
steam

Outputs
9-12 calendered rolls
roll properties

temperature

CD position

pressure

length

# nips

weight

speed
SOP

C
C
S
S

packaged rolls

packaging materials

paper properties

slitters

caliper

winding tension

caliper uniformity

plant environment

density

optical properties

density uniformity

opacity

moisture content

IR transparency

moisture content unif.

internal bond

PTC
Receiving

SOP
operators
QA Testing

width
basis weight

Outputs

9-12 rolls

(UPM)

paper properties

operators

test results for above

Inputs

Inputs

S
S
S
S

Outputs

sample for QA testing

COA

test instruments

Test results

SOPs
operators
test methods

runnability properties
tear strength
tensile strength
surface properties
smoothness (Bekk)
Parker print surf

oil absorbancy

porosity (Bekk)
IGT stain length
optical properties
opacity
IR transparency
sample for QA testing
dirt/debris (slitting)

2008-06-01 SKF Group Slide 25

SKF (Group Six Sigma)

1.18 Process Map

N Noise
! Critical Parameter

0Controllable Parameter
*SOP

Process Map Example

Packaging/Shipping
(UPM)

QA Testing
(UPM)

PTC Receiving

Inputs

C
C
S
C

PC-4
Liner Unwind
Outputs

paperwork
packaged rolls on trucks
operator
COA receipt

Inputs

C
S
S
S
S
C
C
C
C
S
N

paper rolls for coating

rolls entered into inventory
rolls moved into inventory

PC-4
Liner Remoisturization

S
S
S
C
C
C
N

BTG solution
SOP
operator
process variables
steam pressure
# steam bars
liner width y

paper rolls
flying splice system
splice tape
SOP
operator
ramp-up speed
paper properties
runnability props.
roll width
web cleaner
dirt/debris (slitting)

remoist. liner
liner width z

Inputs

C
C
S
S
C
S
N

adhesive
adhesive ct wt
SOP
operator
process variables
coating applicator
plant environment

N
Noise

Critical Parameter
C Controllable Parameter
0
S SOP

web with tension

unused liner
web breaks per yardage
liner free of dirt/debris

Inputs

C
S
N
C
S
S
C
C
C
C
N

SKF (Group Six Sigma)

silicone chemistry
silicone applicator
silicone poisons
silicone coat weight
SOP
operator
process variables
paper properties
runnability props.
surface props.
plant environment

PC-4
Silicone Drying/Curing
Outputs

Inputs

N
S
S
C
C
C
N
N

wet siliconized liner

silicone coverage
silicone uniformity
%moisture
web breaks per yardage

PC-4 Facestock
Lamination
Outputs

adhesive coated liner

adhesive ct wt
adhesive ct wt unif.
web breaks per yardage
adhesive surface roughness

Inputs

C
S
S
C
N
S

facestock
SOP
operator
process variables
plant environment
release tester

Outputs

uncured silicone
SOP
operator
process variables
oven temps.
line speed
plant environment
liner width x

1.18 Process Map

cured silicone
liner width y
web breaks per yardage

PTC
Slitting / Shipping
Outputs
roll laminate constr.
scrap
release
dye stain

Inputs

C
S
S
C
S

Outputs

slitter
SOP
operator
process variables
packaging materials

Customer
Converting

2008-06-01 SKF Group Slide 26

Outputs

PC-4
Adhesive Coating/Drying
Outputs

Inputs

PC-4
Silicone Coating

scrap
packaged slit rolls

Accounts Receivable and Invoicing Process Map

(with data and rework)
Invoice Customer Payment Process
Invoice Sent

Mail Invoice
to Asiana

Invoice Issued
S
C
C
C

Invoice Received

Invoice Document
Price
Quantity
Workscope

S
S
S
C

Invoice Collected by Clerk

Collect
Invoices at
Asiana

7 (7)

Customer Address
Shipping Document
Postal Service (Asia)
Fedex

S
C
N
C

3 (10)

Invoice Distributed to Sections

Distribute
Invoices to
each Section 1 (11)

Mail Box
N Mail Clerk
Mail Checking Frequency
S Classification of Invoice by P.O #
Mail Clerk
Queue Time
Invoice Received
by Each Section

APU R&O

System Input

Payment Voucher

Enter Data
into System
4 (24)
Database

Acceptance Decision

Create
Payment
Voucher

7 (20)

Bank Notified to
Release Payment

Payment Approved

N
C
C
S
N

30 (54)

Notify Bank
to make
Payment

Accounting Rep
Budget Allocation
Purchasing Influence
ATLs Influence
Priority of Payment

N
S
C
S

2 (56)

Finance Rep
Bank Notice
Budget Allocation
Accounts Payable
Payment Submitted

# = Days for process step

(#) = Cumulative Days for process

2008-06-01 SKF Group Slide 27

SKF (Group Six Sigma)

Bank Submits
Payment

1.18 Process Map

Component R&O

Review &
Confirm
2 (13)
Invoice

Accept
Invoice?

N Priority
N Shipment Hold
N AOG
No
S Invoice Data
N Purchasing Manager
C Time to Create Voucher

N Accounting Rep
S Payment Voucher
S Database System

Approve
Payment

Yes
Y

N
S
S
C

APU Purchase

Purchasing Section Manager

Original Quote Documentation
Invoice Documentation
S
Comparison of Quote & Invoice
C
C
N

Part Purchase
Receipt of Invoice
Inbox Location
Queue Time
Purchasing Section Manager

Dispute Resolved

Resolve
Dispute

30 (43)

New Invoice

Re-Issue
Invoice

10 (53)

C Business Unit Involvement S Dispute Resolution Agreement

S Express Mail
S Type of Dispute
(Price, Quantity,Workscope)
N Purchasing Section Manager
S Retrieval of Relevant Files
S ATL Involvement
C Time to Resolve Dispute
C Communication

Rework: Disputed Invoice