High Level - PowerPoint Presentation

Slide1

High Level Process Mapping

Measure

I/O MapSlide2

Objectives

Describe major process steps of a project

Develop a comprehensive list of inputs and outputs required for each step

Classify input variables as S, C, or N in the determination of controllable or noise factors

2Slide3

Remember SIPOC?

I/O Mapping takes a deeper dive in the middle section of the SIPOC

The I/O Map helps team analyze and classify process inputs and outputs

Inputs (X’s) and Outputs (Y’s) are the main emphasis

3Slide4

Definitions

I = Input 

Materials, resources and data required to execute your process

P = Process

Series of steps or activities that uses one or more kinds of inputs and changes them into an output that is of value to the customer

O = Output

Tangible products or services that result from the process and the metrics

4Slide5

Steps for Performing I/O Mapping

Identify all steps in the process

List key output variables at each step

List key input variables and classify process inputs as controllable or uncontrollable

5Slide6

1. Identify the Process Steps

Start with the process steps that defines the start of your process and end of your process

Include

all value-added and non value-added stepsKeep it simple: 4-6 step is ideal, 8-12 maximum

Process steps are actions, use verbs

!

6Slide7

2. Determine the Outputs For Each Step

Identify what the process step “produces”

Two

types of outputs:Process Deliverables: the

actual output of the processBusiness Measures: consequence of running the process; i.e., quality, delivery, or cost/productivity related

Outputs should be:

Measurable

:

use

“bolt length”, not “correct bolts” or “bolt length on target”Specific, not general: use “operator experience” or “analyst typing speed”, not just “operator” or “analyst”

7Slide8

3. Determine the Inputs For Each Step

Identify what

is put into the process step

Inputs should be specific, like outputs

Inputs generally fall into the ‘6 M’ categories (Man, Machine, Materials, Mother Nature, Measurement, and Methods)

Outputs from

one step may become an

Input

to

anotherClassify the Inputs as (S), (C) or (N)(S) Standard Operating Procedure(C) Controllable

(N) Noise or Uncontrolled

8Slide9

Classification Types Defined

(S) Standardized inputs: Input variables under operating Procedure/ Policy or a detailed work instruction for running that process

step

(C) Controllable inputs: Key X’s that are actively controlled and that can be changed to see the effect on the output (Y

)(N) Noise inputs: Input variables (X’s) that impact the output variables (Y’s) but are difficult, impossible or we choose not to control. i.e. – Environmental variables such as humidity or temperature

9Slide10

Discussion

“Baking

a Cake”:

Identify

inputs; classify as S, C, or N

Prepare

Cook

Serve

____________________________________

____________________________________

____________________________________

__________________

__________________

__________________

I

P

O

10Slide11

Operations Example

Surface Prep

Make minor repairs

Sand surface

Clean Surface

Inspect

Prime

Adjust air pressure

Load primer

Record primer lot

Prime surface

Inspect

Paint

Adjust air pressure

Check nozzle type

Inspect surface

Record paint lot

Paint surface

Inspect

Dry

Set oven profile

Inspect surface

Rework

Outputs

Outputs

Clean surface

Surface finish

Prep time

Defect / repair count

Air pressure

Complete coverage

Surface finish

Prime time

Primer lot

Primer thickness

Air pressure

Complete coverage

Surface finish

Paint time

Paint lot

Paint thickness

Dry paint

Surface finish

Dry time

Paint hardness

Defect / repair count

Inputs

Type

Surface contamination

Surface roughness

Chassis

type

Sanding grit

Air pressure

Filler lot

Sander RPM

Surface contamination

Surface roughness

Air pressure

Primer lot

Nozzle type

Primer age

Ambient temp

Relative humidity

N

N

N

C

C

N

C

N

N

C

N

C

N

N

N

Inputs

Type

Surface contamination

Surface roughness

Air pressurePaint lotNozzle typePaint ageAmbient tempRelative humidityPaint viscosity

Chassis typeAir pressureAmbient tempRelative humidityOven profileThermocouple calibrationPaint thickness

NNCNCNNNC

CNNNCCN

11Slide12

Non-Ops Example

Cross reference for P/N’s

Order information

Plant loading information

Order worksheet form

Pricing algorithm

Information from customer

Greeting script

Answering procedure

Telephone system

Type

Outputs

Answer Phone

Greet customer

Determine P/N

Identify need date

Identify ship to address

Identify ship method

Enter Order Information

Input information

Print order confirmation

Determine ship date

Review order

Confirm Order

FAX confirmation to customer

Verify manufacturing receipt of order

Inputs

Type

Order worksheet

Computer entry screens

Lead time information from mfg

Shipment method

Printed confirmation sheet

Production schedule

Customer contact info

Production contact info

Confirmation procedure

N

C

N

C

C

N

C

C

C

Inputs

C

C

C

N

Prompt answer

Live body

Part number

Availability

Need date

Get Internal Information

Get internal P/N

Determine terms

Identify lead time

Complete order worksheet

C

N

N

C

S

Customer number

Order worksheet

Pricing

Outputs

Order in computer

Correct info

Promise date

Order number

Printed confirmation

Time to Enter

Order confirmation to customer

Order to production

12Slide13

Exercise: I/O Process Mapping

Consider the process of making a great cup of

‘Cappuccino’ …With your team, create an I/O Process Map

Identify all steps in the process

List key output variables at each step

List key input

variables

Classify process inputs as controllable or uncontrollable

13Slide14

Review

Describe major process steps of a project

Develop a comprehensive list of inputs and outputs required for each step

Classify input variables as S, C, or N in the determination of controllable or noise factors

14