LEAN 101: VALUE STREAM MAPPING
Published on Nov 19, 2015
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LEAN 101: PROCESS MAPPING
THE MOST DANGEROUS WASTE IS THE KIND WE DON'T SEE
Process mapping is a useful tool in identifying and seeing waste in our work processes. Process maps help us see how material & information flows and how our processes actually operate to produce an end product.
WHAT'S A PROCESS MAP?
LET'S DEFINE IT
A process map is a step-by-step description of all the actions a person takes to convert inputs to outputs. In other words, it's all the steps a person takes to complete a process to produce an end product.
You start with material, parts, information, equipment, or people and put it through a process to get a product, part, service, or information.
We have processes that turn raw material into finished parts, processes that turn finished parts into a machine, processes that turn information into something someone else can use, and so on.
A lot of our processes live in our heads, in the abstract. With process mapping, we take the process out of the abstract and document it on paper. It's a visual of how a process operates step-by-step.
Process maps help us to see where our processes aren't perfect. To some degree our processes contain waste, something that isn't adding value for our customers.
You start with material, parts, information, equipment, or people and put it through a process to get a product, part, service, or information.
We have processes that turn raw material into finished parts, processes that turn finished parts into a machine, processes that turn information into something someone else can use, and so on.
A lot of our processes live in our heads, in the abstract. With process mapping, we take the process out of the abstract and document it on paper. It's a visual of how a process operates step-by-step.
Process maps help us to see where our processes aren't perfect. To some degree our processes contain waste, something that isn't adding value for our customers.
SO WHAT?
WHY USE PROCESS MAPPING?
Why use process mapping?
It's much easier to find and attack waste when it's documented, visual, and in front of us.
It's much easier to find and attack waste when it's documented, visual, and in front of us.
YOU DON'T LEARN TO PROCESS MAP
YOU PROCESS MAP TO LEARN
Creating a process map will help you deeply understand a particular work process.
You don't learn to process map, you process map to learn.
When we create a process map, every single step of a process is there to see, right in front of us. It helps us create that visual connection and makes it easier to spot things that we can improve on.
You don't learn to process map, you process map to learn.
When we create a process map, every single step of a process is there to see, right in front of us. It helps us create that visual connection and makes it easier to spot things that we can improve on.
Photo by niallkennedy
DEPICTS MATERIAL & INFO FLOW
WHAT GOES WHERE AND WHEN
Process maps help us depict the flow of material and information.
We're able to see what needs to happen at each step and when it should happen.
We're able to see what needs to happen at each step and when it should happen.
Photo by ecstaticist
HANDOFFS
WHERE DO THEY OCCUR?
Process maps also help us see where handoffs occur in a process. Process maps help us understand and make clear:
Who receives what information?
When do they receive it?
Who is responsible for doing something with that information?
Who receives what information?
When do they receive it?
Who is responsible for doing something with that information?
DECISIONS
WHERE ARE THEY MADE?
Process maps are also helpful in showing where decisions need to be made within a process.
Just like with handoffs, it's important to know where decisions need to be made and what path the process follows after the decision point.
Just like with handoffs, it's important to know where decisions need to be made and what path the process follows after the decision point.
ROADBLOCKS
WHAT & WHERE ARE THEY?
When we map out a process, we're able to see more clearly where problems, roadblocks, and bottlenecks exist.
Once you know what problems you're trying to tackle, you can use tools like root cause analysis and error proofing to remove them and streamline the process.
Once you know what problems you're trying to tackle, you can use tools like root cause analysis and error proofing to remove them and streamline the process.
ADDING VALUE
IT'S WHAT CUSTOMERS WANT
Process maps help us determine what is of value to the customer.
Remember, value is anything the customer is willing to pay for.
With process mapping, we can analyze each step in the process to determine if it's something that adds value for our customers or if it's non-value-added waste. If it's waste, we can work to reduce or eliminate it from the process.
Remember, value is anything the customer is willing to pay for.
With process mapping, we can analyze each step in the process to determine if it's something that adds value for our customers or if it's non-value-added waste. If it's waste, we can work to reduce or eliminate it from the process.
BASELINE
FOR IMPROVEMENT
Lastly, process maps are our baseline for improvement.
When we map out a process, we start with the current state.
The current state is how the process works TODAY. Before you can improve a process, you need to understand how it currently functions.
So, you begin by mapping WHAT IS, not what you would like the process to be. That comes later.
When we map out a process, we start with the current state.
The current state is how the process works TODAY. Before you can improve a process, you need to understand how it currently functions.
So, you begin by mapping WHAT IS, not what you would like the process to be. That comes later.
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So, you have the current state work process mapped.
You've identified everything that's value-added and non-value-added to the customer.
Now what do you do?
You've identified everything that's value-added and non-value-added to the customer.
Now what do you do?
FUTURE STATE
HOW DO YOU WANT THE PROCESS TO WORK?
Once you've documented how a particular process currently operates, you can begin designing the future state, or how you would like the process to operate.
Photo by seanmcgrath
KEEP IT CLEAN
DON'T ADD WASTE
When we develop future state map of the process, we don't carry over any non-value-added steps from the current state map. We want zero waste or as little waste as possible in the improved process.
Photo by kaiton
TRANSITION
BEGIN THE SHIFT FROM CURRENT TO FUTURE STATE
Once the future state of the process is mapped out, you can begin working toward making those improvements.
How are you going to transition from the current state process to the future state process?
What actions and steps need to be taken to accomplish that?
What are you going to do to make sure nothing relevant to the process falls through the cracks?
These are all questions that need to be addressed to ensure that you successfully transition to the future state process and don't slip back to the old way of doing things.
How are you going to transition from the current state process to the future state process?
What actions and steps need to be taken to accomplish that?
What are you going to do to make sure nothing relevant to the process falls through the cracks?
These are all questions that need to be addressed to ensure that you successfully transition to the future state process and don't slip back to the old way of doing things.
