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Flowchart: Basic Tools For Process Improvement
Flowchart: Basic Tools For Process Improvement
Module 6
FLOWCHART
FLOWCHART
What is a Flowchart?
A Flowchart is a diagram that uses graphic symbols to depict the nature and flow of
the steps in a process (Viewgraph 1). Another name for this tool is "flow diagram."
FLOWCHART
What Is a Flowchart?
A diagram that uses graphic
symbols to depict the nature
and flow of the steps in a
process.
FLOWCHART
VIEWGRAPH 1
FLOWCHART
FLOWCHART
VIEWGRAPH 2
FLOWCHART
Decision
Yes
Connector
Measurement
FLOWCHART
VIEWGRAPH 3
Levels of Flowcharts
MACRO
MINI
Start
Start
Draft
POD
Get rough
draft of POD
Type
POD
Distribute
POD
Is it
approved
?
MICRO
Turn on
computer
Start word
proc. applic.
No
Get
approval
Is
rough in
word proc.
applic.
?
No
Type
rough POD
Yes
Edit POD
Yes
Type
smooth
End
Are
there any
corrections
?
Yes
Make
corrections
No
End
Print POD
FLOWCHART
FLOWCHART
VIEWGRAPH 4
FLOWCHART
Keys to Success
Start with the big picture
Observe the current process
Record process steps
Arrange the sequence of steps
Draw the Flowchart
FLOWCHART
FLOWCHART
VIEWGRAPH 5
FLOWCHART
Collect
inputs
Type
smooth
Draft POD
Sign POD
Type rough
Make copies
Retype POD
Submit to XO
Distribute
No
OK ?
End
Yes
A
FLOWCHART
VIEWGRAPH 6
YN
XO
Collect
input
Draft POD
Type rough
Submit to XO
Retype POD
Type smooth
Make copies
No
Yes
Accept
rough
?
Sign POD
Distribute
FLOWCHART
FLOWCHART
VIEWGRAPH 7
FLOWCHART
YN
type rough
YN
submit rough
to XO
A
POD need
retyped ?
Yes
No
YN type
smooth
XO
sign POD
YN
retype
YN copy and
distribute POD
FLOWCHART
VIEWGRAPH 8
Assemble the
right people
Establish
process boundaries
Are
steps in
sequence
?
No
Yes
Assign Flowchart symbols
Review and
label Flowchart
FLOWCHART
FLOWCHART
VIEWGRAPH 9
11
12
FLOWCHART
NANCY
Decide to
change oil
Warm up engine
BOB
Get rags & tools
No
Oil &
filter on hand
?
Yes
Change oil
& filter
Clean up &
put tools away
FLOWCHART
VIEWGRAPH 10
No
Yes
FLOWCHART
VIEWGRAPH 11
13
Below is a sequence of steps that will help you through an orderly analysis of your
Flowchart (Viewgraph 13).
Step 1 - Examine each process step for the following conditions that indicate a
need to improve the process:
! Bottlenecks. These points in the process where it slows down may be caused
by redundant or unnecessary steps, rework, lack of capacity, or other factors.
In the Fire Drill Preparation example depicted in Viewgraph 15, the "Monitors
go to Logroom to get red hats. . ." step indicates a potential bottleneck. The
rework loop identified as connector "B" is one of several in this diagram.
! Weak links. These are steps where problems occur because of inadequate
training of process workers, equipment that needs to be repaired or replaced,
or insufficient technical documentation. "Inform the drill leader and improvise"
is one of the weak links depicted in Viewgraph 15.
! Poorly defined steps. Steps which are not well-defined may be interpreted and
performed in a different way by each person involved, leading to process
variation. "Improvise" is a poorly defined step in the weak link cited above.
! Cost-added-only steps. Such steps add no value to the output of the process
and should be earmarked for elimination. If the Fire Drill Preparation process
in Viewgraph 15 were depicted as an Opportunity Flowchart, "Search the boat
for red hats" would be one of many cost-added-only steps.
Step 2 - Examine each decision symbol. You may want to collect data on how
often there is a "yes" or "no" answer at decision points marked by a diamondshaped symbol. If most decisions go one way rather than the other, you may be
able to remove this decision point.
14
FLOWCHART
VIEWGRAPH 12
Interpretation Steps
Step 1 -
Step 2 -
Step 3 -
Step 4 -
FLOWCHART
FLOWCHART
VIEWGRAPH 13
15
16
FLOWCHART
FLOWCHART
17
EXERCISE 1
Flowchart for Cut Grass Process
Spouse says
Cut the grass.
Prepare to cut
the grass
Spouse says
Cut grass
Start
lawnmower
Open garage
door
Mow the yard
Pull lawnmower
to driveway
Turn lawnmower
off
Check gas
and oil
Need
gas or
oil
?
Yes
Put in gas
and oil
as needed
Does
lawnmower
need to be
washed
?
No
Yes
Get hose
Wash
mower
Return mower
to garage
Close garage
door
No
FLOWCHART
18
VIEWGRAPH 14
FLOWCHART
FLOWCHART
19
20
FLOWCHART
EXERCISE 3
M
Time 1
First drill
in set?
Put simulation
on the
appropriate
gages
Drill monitors
test the radios
Props
available?
Verify initial
conditions set
No
Yes
No
Search
Torpedo Room
Props?
No
Yes
No
Yes
Yes
Initial
conditions
set?
Find the CO
Inform the drill
leader and improvise
Radios
available?
No
All
personnel
on station
?
No
Yes
Yes
Enough
red hats?
No
Borrow from
Quartermasters
Search the
boat for
red hats
FLOWCHART
FLOWCHART
Discrepancy?
No
Yes
Drill monitors
take station
Find them
and put them
on station
Yes
Radios
still not
available
?
Check with
Radiomen
No
Order initial
conditions set
Yes
Obtain COs
permission
Permission
to
initiate?
No
Correct
discrepancies
for the CO
Yes
Correct it
Initiate
the drill
M
Time 2
VIEWGRAPH 15
21
REFERENCES:
1. Brassard, M. (1988). The Memory Jogger, A Pocket Guide of Tools for
Continuous Improvement, pp. 9 - 13. Methuen, MA: GOAL/QPC.
2. Department of the Navy (November 1992). Fundamentals of Total Quality
Leadership (Instructor Guide), pp. 6-12 - 6-19. San Diego, CA: Navy Personnel
Research and Development Center.
3. Department of the Navy (September 1993). Systems Approach to Process
Improvement (Instructor Guide), pp. 1-60 - 1-63; 5-50 - 5-63. San Diego, CA:
OUSN Total Quality Leadership Office and Navy Personnel Research and
Development Center.
4. Hacquebord, H. (1990). A Strategy for Helping Managers to Change.
5. Tribus, M. (June 1989). Deployment Flowcharting (workbook and videotapes).
Los Angeles, CA: Quality and Productivity, Inc.
22
FLOWCHART
FLOWCHART
What Is a Flowchart?
A diagram that uses graphic
symbols to depict the nature
and flow of the steps in a
process.
VIEWGRAPH 1
VIEWGRAPH 2
FLOWCHART
Start / End
Process Step
Decision
Connector
Measurement
No
Yes
VIEWGRAPH 3
FLOWCHART
Get
approval
Print POD
No
Are
there any
corrections
?
Edit POD
Yes
Is
rough in
word proc.
applic.
?
Start word
proc. applic.
Turn on
computer
Levels of Flowcharts
No
MINI
Start
MACRO
Start
Get rough
draft of POD
End
Type
smooth
Yes
Is it
approved
?
Draft
POD
Type
POD
Distribute
POD
End
FLOWCHART
No
Make
corrections
Type
rough POD
MICRO
Yes
VIEWGRAPH 4
FLOWCHART
Keys to Success
Start with the big picture
Observe the current process
Record process steps
VIEWGRAPH 5
No
Start
Yes
End
Distribute
Make copies
Sign POD
Type
smooth
OK ?
Submit to XO
Type rough
Draft POD
Collect
inputs
Retype POD
FLOWCHART
VIEWGRAPH 6
YN
Type rough
Submit to XO
Retype POD
Type smooth
Make copies
Distribute
No
Yes
VIEWGRAPH 7
Sign POD
Accept
rough
?
XO
FLOWCHART
Yes
YN
retype
VIEWGRAPH 8
YN copy and
distribute POD
XO
sign POD
YN type
smooth
No
POD need
retyped ?
Value Added
CMC collect
input
CMC
draft input
YN
type rough
YN
submit rough
to XO
FLOWCHART
Assemble the
right people
Establish
process boundaries
Are
steps in
sequence
?
Yes
No
Review and
label Flowchart
VIEWGRAPH 9
FLOWCHART
CHUCK
NANCY
BOB
VIEWGRAPH 10
Clean up &
put tools away
Change oil
& filter
Yes
Oil &
filter on hand
?
No
Warm up engine
Decide to
change oil
Changing Oil
FLOWCHART
Clean up
& put tools away
Yes
Warm up engine
VALUE ADDED
No
VIEWGRAPH 11
Changing Oil
FLOWCHART
VIEWGRAPH 12
Interpretation Steps
Step 1 - Examine each process step
VIEWGRAPH 13
FLOWCHART
EXERCISE 1
Prepare to cut
the grass
Put in gas
and oil
as needed
Turn lawnmower
off
Start
lawnmower
Close garage
door
Return mower
to garage
No
Does
Yes
lawnmower
need to be
washed
?
Wash
mower
VIEWGRAPH 14
Get hose
Check gas
and oil
Need
gas or
oil
?
Yes
Pull lawnmower
to driveway
Open garage
door
Spouse says
Cut grass
Spouse says
Cut the grass.
No
FLOWCHART
Complete the
Drill Brief
Yes
First drill
in set?
EXERCISE 3
Drill monitors
test the radios
Props?
Yes
Radios
still not
available
?
No
No
Borrow from
Quartermasters
Yes
Check with
Radiomen
Search the
boat for
red hats
Put simulation
on the
appropriate
gages
No
All
personnel
on station
?
Yes
Yes
Discrepancy?
No
Order initial
conditions set
Correct it
Find them
and put them
on station
Verify initial
conditions set
Initial
conditions
set?
Yes
Find the CO
Obtain COs
permission
Permission
to
initiate?
Yes
Initiate
the drill
M
Time 2
No
Correct
discrepancies
for the CO
VIEWGRAPH 15
No
No
Time 1
No
No
No
Search
Torpedo Room
Props
available?
Yes
Radios
available?
Yes
Enough
red hats?
Yes
Drill monitors
take station
FLOWCHART