6Sigma六西格瑪精益生產(chǎn)持續(xù)改善分析管理常用工具資料 04_ProcMap(流程圖)

1、PAPERWORKTURN STEAM ON TO DICY TANKLOAD DMFLOAD DICYLOAD 2MI1BILL OF MATERIALSISO PROCEDURESREWORKSCALE ACCURACYPREHEATINGLOAD ACCURACYCLEANLINESSRAW MATERIALLOAD ACCURACYENVIRONMENT (HUMIDITY)RAW MATERIALMIXER SPEED LOAD ACCURACYENVIRONMENT (HUMIDITY)RAW MATERIALMIXER SPEED Process MappingChampion

2、Training1Six Sigma Champion Training How does “Process Mapping” fit within the overall Process Improvement Plan (PIP) ?During the Measurement phase of the PIP, it is important to fully understand the process, with its key input and output variables.A Process Map helps us document the process in orde

3、r that we can maintain control and reduce variations, due to process changes over time.Process Mapping2Six Sigma Champion Training I still dont understand how this process flows.Why build a Process Map?Well it sort of goes like this.I think this is what we do next.I know things go in and come out, b

4、ut I dont know how.Are these the typical answers you get to the question “How does it work?”?That cant be the next step. We forgot about the things Marge does.3Six Sigma Champion Training . and thats all there is to this process. All pretty simple. Why dont you get it?I lost you after you said this

5、is where it begins.?Work Flow And Tasks Are Not Well Defined Nor Understood. 4Six Sigma Champion Training Processes can & will cut across a number of Functions and DepartmentsThe linkages among the functions are where processes normally breakdown.PurchasingOperationsFinanceSalesTasksfromthevariousar

6、easfunctionalinvolvedintheprocess5Six Sigma Champion Training What does the Tool Identify? - Process Boundaries - Sub-processes - Major Activities - Key Process Inputs Variables (KPIVs) - Key Process Output Variables (KPOVs) - Value added and non-value added steps in the process - Complexity - Redun

7、dancy What are the Results of Process Mapping? - Identify holes in the existing Control Plan - Opportunity for eliminating steps in the process - Identify measurement systems requiring Gage R&R - Identify Key Output Variables for Capability Studies - Data Collection Points - It becomes a living docu

8、ment which assists in maintaining the FMEA and Control Plan - Training AidProcess Mapping6Six Sigma Champion Training The Process Map has Many UsesProcess maps can be used on any type of process: manufacturing, assembly, service, or administrative. Provides a step-by-step picture of the “as-is” situ

9、ation for discussion and/or communication. Define and highlights areas for improvement in a process These can either be elimination of steps or addition of steps depending on the desired outcome of the process. Outlines a new improved process (“to-be”) while maintaining the benefits of the current p

10、rocess. 7Six Sigma Champion Training Two basic types of Flow MapsTop Level Flow MapMajor Use - to locate critical features and processes for subsequent processingUsually focused on process sequence for a productIt is used to develop the FMEA and Control PlanIt is characterized by a linear flow from

11、one process step to the nextFollows the process sequence, but usually lacks sufficient detail for a new person to successfully complete the task.Detail Process Flow MapMajor Use - to understand details of how a process works, decision pointsUsually focused on one or two processes in a work areaIt is

12、 usually used for Work InstructionsIt is characterized by convoluted decision pathsFollowing the map should lead to successful completion of the task8Six Sigma Champion Training Top Level Flow Mapping - BasicsCreating a Process MapProduct or Process FocusList Key Input VariablesList Key Output Varia

13、bles (i.e. deliverables)Identify value-added and non-value added steps in the process. (process steps, inspection / testing, rework, scrap points)Key Process Input VariablesControllable Inputs: these can be changed and we see an effect in the key output variables. These inputs are sometimes called “

14、knob variables”Critical Inputs: are shown to statistically have major impact on variability of output variablesNoise Inputs: Inputs that impact the outputs but are difficult to control.Standard Operating Procedures: A standard procedure for running the process9Six Sigma Champion Training Example of

15、Top Level Flow MapNote the linear flowNote the key inputs and outputs for the process chainThese key inputs and outputs become the basis for FMEA and Control Plan linkage10Six Sigma Champion Training Your biggest challenge will be to get these qualified people on the assignment. Cross functional rep

16、resentation of all the areas involved Very good understanding of the process both what is and isnt working Willingness to implement changes and make the tough decision Bias for positive action Problem solving logic and skills Considered to be a leader by management, peers, and subordinates Can invol

17、ve and mobilize people Knows the organization, i.e., can serve as a pathfinder - Knowledgeable people, access data and information, remove barriers Available during the course of the projectForm a Process Team11Six Sigma Champion Training Identify value-added and nonvalue-added steps in the process

18、Label Body2Insert Spirol Pin3Assemble Pistons4Assemble Cover5Test6Station 1 Body AssemblyAD-SP Air DryerPaperwork11Non-Value AddedValue AddedValue-added and nonvalue-added Steps in the Process 12Six Sigma Champion Training Assembly AD-SP Air Dryer BodyINPUTSOUTPUTSAssembly LaborProceduresMaterialsEq

19、uipment, FixturesEnvironmentCleanlinessReworkPart to PrintPerformance to SpecVisually acceptableLeak freeIdentifiedCleanPackaged for useConsistent standardList General Input and major Customer Key Output VariablesGeneral Input Variables and Major Customer Key Output Variables13Six Sigma Champion Tra

20、ining Show Key Outputs (KPOVs) at each process step Key Outputs (Deliverables)14Six Sigma Champion Training List and classify Key Inputs (KPIVs) at each process stepLabel Body2Insert Spirol Pin3Assemble Pistons4Assemble Cover5Test6Station 1 Body AssemblyAD-SP Air DryerPaperwork1Bills of materialsISO

21、 ProceduresCleanlinessMaterialPress ForceMaterialAssy TechniqueAmount of GreaseMaterialAssy techniqueAdjustment Pos.Snap Ring InsertionMaterialTest CapabilityCalibration1CRITICAL NOISESOPCONTROLLABLE Step 6: Key Inputs15Six Sigma Champion Training Controllable Inputs: KPIVs that can be changed to se

22、e the effect on KPOVs. Sometimes called “Knob” VariablesCritical Inputs: KPIVs that have been statistically shown to have a major impact on the variability of the KPOVs.Noise Inputs: Input variables that impact the KPOVs but are difficult or impossible to control. Example: Environmental variables su

23、ch as humidity, temperatureStandard Operating Procedures: A standard procedure for running the processKey Process Input Variables (KPIVs)16Six Sigma Champion Training Add the Operating Specifications and Process Targets for the Controllable and Critical InputsCRITICALNOISESOPCONTROLLABLEOperating Sp

24、ecifications17Six Sigma Champion Training At this time begin gathering information from the people on where the issues may lie.Typical Order Fulfillment ProcessCustomer Places OrderSend order to warehouse for pickingIs order correct?NoYesCall Customer and make corrections.IsProduct Available?NoYesPi

25、ck product for orderDoes Customer have other shipments?YesNoWill product be available before order ships?YesPlace order on hold until product availableCancel OrderNoIs production scheduled to manufacture product?Can production manufacture product in time for shipping?NoYesNoWill Customer accept back

26、orders?YesExpedite manufacturing scheduleNoShip OrderYesWill Customer allow consolidated shipments?YesNoConsolidate OrdersCustomer Receives OrderOrder EntryWarehousingSalesManufacturingTransportationDo you think this represents the overall process?I think this is pretty much what we do around here.V

27、alidate the Process with Groups of People who work with the Process on a daily basis18Six Sigma Champion Training If I only knew what I was trying to find in this process maybe I could have more success at fixing the problems!The first step is understanding what is really going on within the process

28、. Only then can you begin to understand the magnitude and try to fix it.Analyze the Process MapNow that we have built the Process Map, we can begin to Analyze the Data and Create Information19Six Sigma Champion Training Should Describe:Major activities/tasksSub-processesProcess BoundariesKPIVs (Xs)KPOVs (Ys)Should be reviewed frequently and updatedProcess Mapping Complete20Six Sigma Champion Training PAPERWORKTURN STEAM ON TO DICY TANKLOAD DMFLOAD DICYLOAD 2MI1BILL OF MATERIAL