Continuous Improvement Toolkit Flow Process Chart
The Continuous Improvement Map Managing Risk FMEA Understanding Performance Check Sheets Data Collection PDPC RAID Log* Risk Assessment* Fault Tree Analysis Traffic Light Assessment Lean Measures Bottleneck Analysis** Process Yield Capability Indices Gap Analysis* Reliability Analysis Benchmarking** Data collection planner* Questionnaires Force Field Analysis Decision Tree Kano Analysis Interviews Control Charts Focus Groups Observations Critical-to Tree KPIs Graphical Analysis MSA Decision Balance Sheet Break-even Analysis Cost of Quality* OEE Descriptive Statistics Probability Distributions Histograms & Boxplots Run Charts Sampling Brainstorming Deciding & Selecting Pick Chart QFD Matrix Diagram Pugh Matrix Voting Pareto Analysis ANOVA 5 Whys Fishbone Diagram SCAMPER** Importance-Urgency Mapping Cost Benefit Analysis Paired Comparison Prioritization Matrix C&E Matrix Hypothesis Testing Morphological Analysis Affinity Diagram Mind Mapping* Suggestion systems Chi-Square Multi vari Studies Scatter Plots TPN Analysis Four Field Matrix Portfolio Matrix Correlation Root Cause Analysis Design of Experiment Tree Diagram* Attribute Analysis Relationship Mapping* Lateral Thinking Creating Ideas DMAIC Understanding Cause & Effect Confidence Intervals Regression How-How Diagram** Flowcharting Planning & Project Management* MOST SWOT Analysis Project Charter A3 Thinking SIPOC* PDCA Data Snooping Daily Planning RACI Matrix Kaizen Events Cross Training Value Analysis Mistake Proofing Simulation Waste Analysis Flow Process Charts IDEF0 Stakeholder Analysis Improvement Roadmaps Policy Deployment Standard work Pull Flow Visual Management Process Redesign Spaghetti Diagram Control Planning TPM PERT/CPM Activity Networks Gantt Charts Document control Implementing Solutions** Ergonomics Automation Just in Time 5S Quick Changeover Time Value Map Value Stream Mapping Service Blueprints Process Mapping Designing & Analyzing Processes
A symbolic representation. Illustrates the sequence of actions within a process. Records the steps of a process along a vertical line. Used when analyzing the steps in a process. Helps identify and eliminate waste. Sometimes called process sequence chart.
It can be drawn up as the process is happening. This allows getting an accurate description of the process. A person for example can follow a part, noting how and when it is produced, moved, checked and stored. This ensures that what actually happens gets recorded. Later when analyzing the process, some steps become obvious candidates for improvement such as: Non-value-adding activities. Long delays. Excessive transportation.
-- Flow Process Chart Common Process Problems: Non-value adding steps. Errors and rework. Unnecessary activities and duplication. Bottlenecks. Long cycle times and excessive delays. Missing and unclear steps. Too many inspections or checks. Complex procedures. Departure from procedure. Dead ends. Costly steps. Muda
Common Symbols: Operation produce or process something. Inspection checking of items to ensure correct quality or quantity. Storage storing materials or other items. Transport movement of people, materials or other items. Delay idle time of people, material or machinery. Operation Transport Inspection Delay Storage Rejection point
Three Types: A man-type chart which shows the actions of a person. A material-type chart which shows what happens to a product or item. An equipment-type chart which shows how a tool or other piece of equipment is used.
Example Material Type Chart Egg Tray Production Process: Waste paper in store Inspecting and counting Convey to mixer Staking for packing Pulping and mixing Packing Convey to forming machine Convey to warehouse Forming Egg trays in store Drying
Example Supplier Invoice Processing: 15 minutes 10 minutes 5 minutes 60 minutes 5 minutes Enter invoice into system Match invoice to purchase order Send for authorization Wait for payment to be authorized Bring back to the Accounts Office 30 minutes Pay the supplier
Example Supplier Invoice Processing: Step # Time (min) Distance (meters) Step Description 1 15 X Enter invoice into system 2 10 X Match invoice to purchase order 3 2 85 X Send for authorization 4 60 X Wait for payment to be authorized 5 2 85 X Bring back to the Accounts Office 6 25 X Pay the supplier
Example Supplier Invoice Processing: Number of steps Time (min) Distance (meters) Operation Transport Inspection Delay Store 2 2 1 1 0 40 4 10 60 0-170 - - -
-- Flow Process Chart Further Information: What do we think of a process is not necessary what it actually is. What you think it is What it actually is What you would like it to be Hidden factors
-- Flow Process Chart Example Can Making Process: Start From IBO De-Reeler Lubricator Cupper Coater Body Maker 8 Body Maker 4 BRC? Base Rim Coater Dropout Fallen? Scrap Dropout Fallen? Scrap Body Maker 7 Body Maker 3 Coater Oven 595 Palletiser Body Maker 6 Body Maker 2 240 Strapper Body Maker 5 Body Maker 1 Decorator Overvarnish 2200 Strapper BRC Dropout Washer Fallen? Scrap Decorator Oven Light Tester Light? Scrap Pickup to Warehouse Washer Oven Auto Sampling Inspection AV Camera Defect? Scrap End Rogue Can Detector Rogue? Scrap Cold Room LSM 1 LSM 2 LSM 3 LSM 4 LSM 5 LSM 6 IBO