This document provides an overview of process mapping. It defines a process map as a graphical representation of a process's flow that contains information to improve the process. Process mapping reveals hidden aspects of processes and allows for thorough examination. Building an accurate process map is important as it can be used as input for other improvement tools like fishbone diagrams and FMEAs. The document reviews how to scope a process, select a team, map steps and flows, identify inputs and outputs, and integrate process mapping into standard operating procedures.

1. 1
Process Mapping

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Process Mapping
Learning Objectives
 Overview of a Process Map
 Benefits of Process Mapping
 Learn how to build a Process Map, step by step
 Difference between Top Level Map & a Detail
Map
 Learn how Process Mapping fits into process
improvement activities
 Complete a Process Mapping Exercise
 Learn how to integrate Process Mapping into
your Company SOPs

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Process Mapping
What is a Process Map?
 Is a graphical representation of the flow
of a process
 It contains information that is beneficial
to improving the process
 It represents the process as it actually
exists

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Process Mapping
No
Yes
Customer places
order
Is order
Correct?
Send order to
Warehouse for picking
Is product
Available?
Pick product for
order
Does customer have
Other shipments?
Ship order
Customer receive
order
Will customer allow
Consolidated shipments?
Consolidated orders
Will product
Be available
Before order ships?
Is production schedule
To manufacture
Product?
Can production
Manufacture
Product in time
For shipping?
Will customer
Accept back
Order?
Cancel order
Expedite manufacturing
schedule
Place order on hold
Until product
available
Call customer and
Make corrections
Yes
No
Yes
No
Yes
Yes
No
No
Yes Yes
No No
Yes
No
Typical Order Fulfillment Process
Sales OrderEntry Warehousing Transportation
Example of a Process Map

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Process Mapping
Key Elements of a Process Map
 Should Describe:
 Major activities/tasks
 Sub-processes
 Process Boundaries (top level vs. detail)
 Process Inputs X’s
 Process outputs Y’s
 Process step outputs y’s
 Should be reviewed frequently and updated
y f x x xk
 ( , ,..., )
1 2

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Process Mapping
Benefits of Process Mapping
 Reveals “Hidden Factories”
 Exposes inaccurate assumptions, beliefs, and
understandings
 Enables rigorous, thorough examination of the
outputs and inputs
 Increases probability of capturing all the y’s
and x’s
 Increases probability of getting to y = f(x).
 Identification of outputs needing measurement
studies
 Identification of outputs for capability studies
 Opportunities for elimination of non-value-added
steps or addition of needed steps
 Can provide a snapshot for future comparisons

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Process Mapping
Building a Process Map
What is a work process?
INPUT OUTPUT
PROCESS
Transformation
(Value-Added)
Steps

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Process Mapping
 Determine scope of the process as it
relates to the project/product
 Large, cross-functional processes
that involve many people are called
macro processes. Executives tend to
view the organization in this manner.
 Smaller, local processes are called
micro processes. This is the view of
line employees and first line
management.
 The scope of the process must be
defined at an actionable level.
*
Building a Process Map
Process Scope
Select Right
Team
Map:
Primary Process
Alternative Paths
Inspection Points
Use Map to
Improve
Process

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Process Mapping
Team Formation
 Manufacturing Engineers
 ME Technicians
 Design Engineering
 Line Operators
 Line Supervisors
 Maintenance Technicians
*
Building a Process Map
Process Scope
Select Right
Team
Map:
Primary Process
Alternative Paths
Inspection Points
Use Map to
Improve
Process

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Process Mapping
Building a Process Map
Process Scope
Select Right
Team
Map:
Primary Process
Alternative Paths
Inspection Points
Use Map to
Improve
Process KEY PROCESS
INPUT VARIABLES
KEY PROCESS
OUTPUT VARIABLES
X’s MANAGE
Y’s CORRECT, IN-SPEC
KPIV KPIV KPIV
PROCESS
VALUE-ADDED STEPS
KPOV KPOV
DEFECT-FREE
CTQ

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Process Mapping
Process Flow Symbols
OPERATION
All steps in the process where the object undergoes a
change in form or condition.
TRANSPORTATION
All steps in a process where the object moves from one
location to another, outside of the Operation
STORAGE
All steps in the process where the object remains at rest, in
a semi-permanent or storage condition
DELAY
All incidences where the object stops or waits on a an
operation, transportation, or inspection
INSPECTION
All steps in the process where the objects are checked for
completeness, quality, outside of the Operation.
DECISION

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Process Mapping
Dryer Body
Assembly
INPUTS OUTPUTS
(Big Y’s)
Assembly Labor
Procedures
Materials
Equipment, Fixtures
Environment
Cleanliness
Rework
Part to Print
Performance to Spec
Visually acceptable
Leak free
Identified
Clean
Packaged for use
Consistent standard
Develop an Upper Level
Process Map
 Identify Major Inputs and Customer Outputs
for the Suspect Process
 Identify Possible Connections

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Process Mapping
Identify Process Steps Within
Boundaries
Label Body
2
Insert Spirol
Pin
3
Assemble
Pistons
4
Assemble
Cover
5
Dryer
Paperwork
1
Test
6
Why is one of the steps a
diamond?
7
Store
Dryer Body
Assembly

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Process Mapping
Map Inspection Points
 Signaled by a decision diamond
 Decision diamonds must pose a
question -- no exceptions -- remains
consistent with Mapping Alternative
Paths.
 An inspection point creates a pass or
fail decision based on objective
standards
 Inspections may lead to a reversal of
process flow direction, rework loop
or a scrap.
 Specific, objective questions are
almost always better.
6
Test
Is the pin seated correctly?
Does the O ring function properly?
Is the cover aligned correctly?

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Process Mapping
List Output Variables
(little y’s) for Each Step
Is the pin seated correctly?
Does the O ring function properly?
Is the cover aligned correctly?
How do little y’s relate to big Y’s? What if they don’t?
2
Insert Spirol
Pin
3
Assemble
Pistons
4
Assemble
Cover
5
Dryer Body Assembly
Paperwork
1
Route Ticket
Orientation
Label adhesion
Greased O ring
Screw position adj.
Flush w/ surface
Label Body
O ring position
Cover orientation
Snap ring inserted
Functional
Assembly
Rework
Test
6 7
Store

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Process Mapping
List Inputs (x’s) for each
Process Step
2
Insert Spirol
Pin
3
Assemble
Pistons
4
Assemble
Cover
5
Dryer Body Assembly
Paperwork
1 7
Route Ticket
Orientation
Label adhesion
Greased O ring
Screw position adj.
Flush w/ surface
Label Body
O ring position
Cover orientation
Snap ring inserted
Stores
Functional
Assembly
Rework
Bills of materials
ISO Procedures
Cleanliness
Material
Press Force
Material
Assy Technique
Amount of Grease
Material
Assy technique
Adjustment Pos.
Snap Ring
Insertion
Material
Test Capability
Calibration
Test
6
Is the pin seated correctly?
Does the O ring function properly?
Is the cover aligned correctly?
How do the x’s relate to big Y’s and small y’s?
7
Store

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Process Mapping
Versions of a Process
What You Think It Is... What It Actually Is... What You Would Like...
AT LEAST THREE

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Process Mapping
Manufacturing Variation Causes A "Hidden Factory"
Increased Cost - Lost Capacity
The process map reveals this hidden factory
Yield After
Inspection or Test
Each defect must be detected, repaired and
placed back in the process. Each defect
costs time and money.
Scrap
Rework
Hidden Factory
NOT
OK
Operation
Inputs Inspect First Time
Yield
OK
• Wasted Time
• Wasted Money
• Wasted Resources
• Wasted Floor space
90%
Customer Quality
Defects and the Hidden Factory

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Process Mapping
Add the operating specifications and
process targets for the Controllable and
Critical Inputs (if available)
X Critical
N Noise
S SOP
C Controllable
2
Insert Spirol
Pin
3
Assemble
Pistons
4
Assemble
Cover
5
Paperwork
1
Route Ticket
Orientation
Label adhesion
Greased O ring
Screw position adj.
Flush w/ surface
Label Body
O ring position
Cover orientation
Snap ring inserted
Functional
Assembly
Rework
Dryer Body Assembly
Test
6
Is the pin seated correctly?
Does the O ring function properly?
Is the cover aligned correctly?
S Bills of materials
S ISO Procedures
S Cleanliness
C Material
X Press Force
C Material
S Assy Technique
C Amount of Grease
C Material
S Assy technique
N Adjustment Pos.
C Snap Ring
C Insertion
C Material
X Test Capability
S Calibration
7
Store
Controllable Input Variable Target Upper Spec Lower Spec
Press Force 10 lbs 12 lbs 8 lbs
Amount of Grease 2 cc's 1.5 cc's 2.5 cc's
Adj Pos'n 3 turns 3.5 turns 2.5 turns

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Process Mapping
A process map which accurately and
completely describes the process is
important because it serves as input
to:
– Fishbone Diagram
– the Cause and Effects Matrix
– the FMEA
– the Control Plan Summary
– the Capability Summary
– Multi-vari studies
– Rolled Throughput Yield
How Process mapping can Fit into
Process Improvement Activities
Process Scope
Select Right
Team
Map:
Primary Process
Alternative Paths
Inspection Points
Use Map to
Improve
Process

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Process Mapping
How Process mapping can Fit into
Process Improvement Activities
Process Map
6 3 138
16 Catalyst Stripper
Pluggage 3 6 5 3 137
111 Drying Decomposition 2 6 3 2 2 134
39 Drier Water Carryover 4 6 5 1 132
34 Drier Molecular Sieve 3 3 2 7 2 125
Cause and
Effects Matrix
Process
Step/Part
Number
Potential Failure Mode
Potential Failure Effects
S
E
V
Potential Causes
O
C
C
Current Controls
D
E
T
RPN Actions
Recommended
Resp.
FMEA Initial Assessment of Capabilities
and Control Plans
PAPERWORK TURN STEAM ON
TO DICY TANK
LOAD DMF LOAD DICY LOAD 2MI 1
BILL OF MATERIALS
ISO PROCEDURES
REWORK
SCALE ACCURACY
PREHEATING
LOAD ACCURACY
CLEANLINESS
RAW MATERIAL
LOAD ACCURACY
ENVIRONMENT
(HUMIDITY)
RAW MATERIAL
MIXER SPEED
LOAD ACCURACY
ENVIRONMENT
(HUMIDITY)
RAW MATERIAL
MIXER SPEED
1 2 3 4 5 6 7 8 9 10 11
Process Step Process Inputs
Heavies
in
Product
Lights
in
Product
Moisture
in
Product
Acidity
in
Product
Low
Capacity
From
Unit
Excessive
Downtime
Material
Losses
Corrosion
of
Equipment
Poor
Reactor
Performance
Total
139 Day TanksAnalysis 10 10 9 9 335
9 Reactor Cat./HF Ratio 5 8 7 157
7 Reactor Rxr Temperature 6 5 4 7 149
73 Lights Removal
Condenser Leak 4 8 2 4 1 148
74 Lights Removal
Reboiler Leak 4 8 2 4 1 148
131 PurificationLow Stages 8 8 144
144 Final Storage
Containers 3 2 6 6 140
100 Neutralization
pH Value 6
Process Step Input Output
Process
Specification
(Target, LSL, USL)
Cpk
Mean - Sigma
Measurement
Technique
%R&R
P/T
Sample
Size
Sample
Frequency
Control
Method
Reaction Plan
Coating Dosage 22.5, 22, 23 1.22 UIL-1700 25% 1/hr Auto-timer Cross check
Coating
Height
24,23,25 1.54 Micrometer 31%/0.4735 pts per
panel
1/hr Coating &
pump
speed
Adjust previous
Coating
width
14,12,16 1.78 Laser Measuring
Device
1/hr None in place
Coating
length
36,34,38 1.43 Laser Measuring
Device
1/hr None in place
Vacuum 35" Hg Vacuum Gauge 1/hr Monitor Compare
guages, look
for blockage
COATING &
IMAGING
DIRTY PHOTOMASK
MICROCRACKING,
DELAMINATION, STREAKS
8
LOW FREQUENCY OF CLEANING
8
SOP, VISUAL INSPECTION
7 448
INCREASE FREQUENCY
TO ONCE EVERY 20
PANELS
MG
IMPROVE CLEANING
METHOD
PF
PURCHASE OFF-LINE
CLEANING SYSTEM
MG
TEST ON-LINE MASK
REPLACEMENT
PF
The Big Picture

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Process Mapping
Integrating Process Mapping into SOPs
Example: Process Mapping in First Article.
SPQP and FA
checklist to
include Process
Mapping
SPQP and FA
checklist to
include Process
Mapping
Section of FA Procedure

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Process Mapping
Customer
triggers
SCAR
Suppliers identifies
potential process steps
where root causes
may be found
Process map of the
process steps involved
(Micro)
Fishbone diagram to
Brainstorm / identify
root cause
Further
Actions
Example: Process Mapping in SCAR
Integrating Process Mapping into SOPs

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Process Mapping
Link Tools Integration Tasks to Work
Breakdown Structure
S/N Tasks Task Owner Target
Completion Date
Specific Training
needed for Task
Owner/ Date
Core Team
Member In
Charge
Internal Verified
Date
Group Phase
End Date
Group 1 Tools
1 FA
1.Integrate Process Mapping
into FA procedure/system
Nick 10-Dec-01 Process Mapping
- 15-Nov-01
Yu 15-Dec-01 31-Dec-01
2. Incorporate Process
Mapping in FA package
13-Dec-01
2 SCAR
1. Integrate Process Mapping
into SCAR procedure/system
James 10-Dec-01 Process Mapping
- 15-Nov-01
William 15-Dec-01 31-Dec-01
The effort to integrate Process Mapping into FA and
SCAR procedures should be translated into specific
tasks in the Work Breakdown Structure.

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Process Mapping
Process Mapping Helpful Hints
 Always Process map with a team. Rarely, does one
person have all process knowledge.
 Interrogate the process by watching in many different
conditions.
 You must watch the process as it happens to see the
detail you need.
 Maintain your Process Maps with dates and update
them as necessary. Use them as a reference.
 When to update a Process map? Whenever a change
is being considered to a product’s design, application,
environment, material, or to a product’s manufacturing
or assembly processes.

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Process Mapping
End of Topic
Any question?

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Process Mapping
Reading Reference
Basic Statistics Tools for
Continuous Improvement,
Mark J Kiemele, Stephen R
Schmidt, Ronald J Berdine,
Air Academy Press,
ISBN 1-880156-06-7

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Process Mapping
Process Map Example: Athena Front End
Mechanical Texture
(45mins soak in
piggy back)
1st Wash
Double Scrub Oliver
Kitting
Laser Texture
2nd Wash
Post Laser Oliver
Wash
Ultrafab Wash
QC Optics
(3disks / 3hrs)
Pass?
Sputter
RMM, Raman, N&K
(1disk/0.5hr)
XRF (1disk/2hr)
Pass?
Lube
WIP
Backend
Process
WIP <
4hrs
Ra / Line Density
(1/200)
Pass?
Yes
u/s wash,
create AUT lot
No
repolish,
adjust EDC
QC Optics
(3 discs / 3 hrs)
Pass?
Yes
Rewash all samples
Resample failure
Down for Eng'rg/Maint on
2nd failure
Phase Shift
(1/200 discs)
Pass?
Fail - repolished,
resample
Down for Eng'rg/
Maint on 2nd failure
No
WIP <= 3 hrs?
Yes
No
Yes
Yes
No
Rewash all samples
Resample failure
Down for Eng'rg/Maint on
2nd failure
No
Yes
No
Fail - carbon strip
Resample failure
Down for Eng'rg/Maint on
2nd failure

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Process Mapping
6s Project
Filename Author Date
Process Map Overview
PRIME FLOW ( Modular Cell )
Pallet
Unload
Modular
Merge
Flex/Filter
Install
PASS ?
Clamp
Ring
Install
Disc
Stack
Pallet
Load
RVA
(Sampling)
Balance
Verify
Balance
Correct
Balance
Check
Top Cover
Install
DAC
(Sampling)
Loading of
Components
/ Inspection
Return
Conveyor
(Pallets)
Yes
DEBUG
No
Test Area
Sub-
Assembly
Reruns
Reruns
Rework
Hidden Factory !!!
Appendix 1