Measure

Module 1

Process Mapping
& SIPOC Analysis
1
 Project Process C&E
FMEA
Definition Map Matrix

• Shows actual , • Relates process • Documents risks

including hidden inputs to out puts / associated with
Processes specifications process failure
modes

2
Process Mapping-Getting started….

• Macro map
• Process Flow Diagram (PFD)
• Detailed Process Table
 Laying Cutting Numbering

 Macro Map is a high level process chart

usually showing several steps on both sides of the
project scope
 Rework

Cutting Numbering Bundling QC

 Process Flow Diagram is a detailed map of

every step in the process including the hidden
factory. PFD uses standard symbols.
Process Function

Decision Box

Process Flow direction

Re-Work Box

6
 Identifying VA & NVA….
Rework

Panel
Cutting Numbering Numbering
Inspection

• A Value added process step

should change the product in a
way that is meaningful to the
customer
• Non value added steps do not
change the fit, form or function
of the Product in a way that is
meaningful to the customer
 Identifying VA & NVA….
Rework

Panel
Cutting Numbering Bundling
Inspection

VA ? NVA ? NVA ? VA ?
 Inputs Outputs
Customer
Supplier Targeted
process sections
Process sections Process section

 SIPOC – is the identified target section for Six sigma

activity.
SIPOC –Input & Output
Identification….
SIPOC – Constructing a Detailed
Process Table….
SIPOC – Constructing a Detailed
Process Table….
 SIPOC – Constructing a Detailed
Process Table….
Process VA SOP Inputs I/O Specifications C Capability
Step or # & Outputs Type or
NVA N
 SIPOC – Constructing a Detailed
Process Table….
Process VA SOP Inputs I/O Specifications C Capability
Step or # & Outputs Type or
NVA N
Laying VA # 36 Fabric
Laying Speed
Operator
Lay Plan
Laid Fabric
Cutting VA # 37 Cut Plan
Gerber
Marker
 SIPOC – Constructing a Detailed
Process Table….
Process VA SOP Inputs I/O Specifications C Capability
Step or # & Outputs Type or
NVA N
Laying VA # 36 Fabric Input
Laying Speed Input
Operator Input
Lay Plan Input
Laid Fabric Output
Cutting VA # 37 Cut Plan Input
Gerber Input
Marker Input
 SIPOC – Constructing a Detailed
Process Table….
Process VA SOP Inputs I/O Specifications C Capability
Step or # & Outputs Type or
NVA N
Laying VA # 36 Fabric Input Relaxed for 30 Mins
Laying Speed Input 7-10 yds / s
Operator Input Exp. More than 1 Year
Lay Plan Input Available before 24 Hrs
Laid Fabric Output Not more than 75 plies
Cutting VA # 37 Cut Plan Input
Gerber Input
Marker Input
 SIPOC – Constructing a Detailed
Process Table….
Process VA SOP Inputs I/O Specifications C Capability
Step or # & Outputs Type or
NVA N
Laying VA # 36 Fabric Input Relaxed for 30 Mins C
Laying Speed Input 7-10 yds / s C
Operator Input Exp. More than 1 Year C
Lay Plan Input Available before 24 Hrs C
Laid Fabric Output Not more than 75 plies C
Cutting VA # 37 Cut Plan Input
Gerber Input
Marker Input
 SIPOC – Constructing a Detailed
Process Table….
Process VA SOP Inputs I/O Specifications C Capability
Step or # & Outputs Type or
NVA N
Laying VA # 36 Fabric Input Relaxed for 30 Mins C Unknown
Laying Speed Input 7-10 yds / s C 2 Sigma
Operator Input Exp. More than 1 Year C Unknown
Lay Plan Input Available before 24 Hrs C Unknown
Laid Fabric Output Not more than 75 plies C 3 Sigma
Cutting VA # 37 Cut Plan Input
Gerber Input
Marker Input
 Process Mapping
 Macro Map
 Shows the scope of the project
 Illustrates the where the critical process fits into the bigger picture

 Process Flow Diagram (PFD)

 Establishes a foundation for actions on the process, agreed on by the
team
 Locates Hidden Factories

 Detailed Process Table

 Identifies all the inputs with sufficient details for action
 Provides the inputs to the C&E Matrix, Fishbone Diagrams & FMEA.