1.18 Process Map Rev RK 20080601

Week 1

2008-06-01 © SKF Group Slide 1 SKF (Group Six Sigma) 1.18 Process Map
Detailed mapping can be used and be useful for ANY process.
Such Maps are required for every Six Sigma project.

Detailed mapping can be used and be useful for ANY process.
Such Maps are required for every Six Sigma project.
Process Mapping Objectives
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SKF Six Sigma Roadmap
Define Measure Analyse Improve Control Project Charter
SIPOC
Value Stream Map and Lean Tools
Process Map
Measurement Systems Analysis
Data Collection & Sampling
Statistical Process Behaviour

Inputs Outputs
TransformationPeople
Equipment
Materials
Supplies
Information
Products
Goods
Services
Consequences

A process is a series of activities that transforms a set of inputs into a specific set of outputs.
Y=f(XY=f(X11

Process maps are a visual representation of:

Y=f(XY=f(X11

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Process Maps describe
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Outputs (y’s or Y’s) being measured or in need of measurement
systems
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/Process Map = Process Flow Chart

Process Map
process
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actually works
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procedure, for example)
variation

Process Maps and Flow Charts
Process Maps drive reduction
F E E D

Preparing the Process Map

5 Easy Steps
2.
3.
4.
and classify
Operating Procedure
controllable and critical inputs

Process Owner: __________
Inputs Outputs

Valve Body Blanks from Dept. 30
Audit & Sort Blanks on
Broach Splines
Face, Bore & C’Bore the Slotted End
Wash
T r u c k P a r t s
t o R e w o r k A r e a
Drill Missing Holes
Wash
Y
N
Y
Sort by ID GroovesInspect
Press In Sleeves
Grind Sleeve OD
Auto- Inspect
Press Force
Rough ID
N Scrap
Step 2: Identify all steps in the Process
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Finish OD & Wire Brush

Finish OD & Wire Brush
Outputs
Ground ID at 29.289/29.307 mm Run-out to OD 0.006 mm Taper, roundness, & straightness of 0.001 mm
Audit for ID
Step 3: Show Key Outputs at each step

Key: !

S-
Inputs
S-
Outputs
Ground ID at 29.289/29.307 mm Run-out to OD 0.006 mm Taper, roundness, & straightness
of 0.001 mm
Audit for ID
Step 4: List Key Inputs and

Process Input Variables (x’s)
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Key: !
Outputs
Ground ID at 29.289/29.307 mm Run-out to OD 0.006 mm Taper, roundness, & straightness
of 0.001 mm
Audit for ID

S-
Step 5: Add the Operating Specifications and Process Targets
Controllable/Critical Input Parameter Target
Upper spec
Lower spec

Process Mapping is the foundation for continuous improvement.

FMEA
MSA
DOE
SPC
Good DRY coverage V.C. Ctwt distribution Moisture
Pressure Filters
Adhesive to die CR2
Speed Temperature Silicone coverage die settings ⇑ Back up roll die settings
Temp profile Inert gas flow Nozzle velocities Oven settings
Pressure Filters
Steam Pressure Air temp differential speed Roll Pressure ⇑ Face Moisture
Rolls of good product
Coating Drying1st Filtration Rehumidification

Team Exercise
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Catapult Exercise
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You have been selected to serve on the Company’s elite catapult
squad. Your mission is to optimise the catapult “process”

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A successful catapult squad can place a projectile on target nearly
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Good luck! The penalties for failure are severe!! (Remember, this is
the 11th

Process Mapping Exercise
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Work with your breakout group to create a Map for the catapult
process, based on your observations from the video.
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needed). Select a spokesperson to debrief the class.
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Process Mapping Summary
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The result of a process depends on the steps and the inputs
Y = f(X)
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Update the Process Map every time that an input appears to be
critical

SKF

Inputs Outputs Inputs Outputs Inputs Outputs
C fiber type uncalendered sheet C! supercalender factors 9-12 calendered rolls C 9-12 rolls packaged rolls
C! papermaking factors basis weight C steam roll properties C packaging materials paper propert ies
S paper machine caliper C temperature CD position S SOP
S SOP caliper uniformity C pressure length S operators
S operators density C # nips weight
C wet end additives density uniformity C speed width
C size press moisture content S SOP paper properties
C size coating moisture content unif. S operators basis weight
runnability properties C slitters caliper Inputs Outputs
tear strength C winding tension caliper uniformity
tensile strength N plant environment density sample for QA testing COA
optical properties density uniformity S test instruments Test results
opacity moisture content S SOPs
IR transparency moisture content unif. S operators
test results for above internal bond S test methods
runnability properties
tear strength
tensile strength
Parker print surf 0 oil absorbancy * porosity (Bekk)
IGT stain length

Inputs Outputs Inputs Outputs Inputs Outputs Inputs Outputs
C paperwork paper rolls for coating C paper rolls web with tension C sil icone chemistry wet s il iconized liner N uncured sil icone cured sil icone C packaged rolls on trucks rolls entered into inventory S flying splice system unused liner S silicone applicator s ilicone coverage S SOP liner width y S operator rolls moved into inventory S splice tape web breaks per yardage N silicone poisons silicone uniformity S operator web breaks per yardage C COA receipt S SOP liner free of dirt/debris C silicone coat weight %mois ture C process variables
S operator S SOP web breaks per yardage C oven temps. C ramp-up speed S operator C line speed C paper properties C process variables N plant environment C runnability props. C paper properties N liner width x C roll width C runnability props. S web cleaner C surface props. N dirt/debris (slitting) N plant environment
Inputs Outputs Inputs Outputs Inputs Outputs Inputs Outputs
S BTG solution remoist. liner C adhesive adhesive coated liner C facestock roll laminate constr. C slitter scrap S SOP liner width z C adhesive ct wt adhesive ct wt S SOP scrap S SOP packaged slit rolls S operator S SOP adhesive ct wt unif. S operator release S operator C process variables S operator web breaks per yardage C process variables dye stain C process variables C steam pressure C process variables adhesive surface roughness N plant environment S packaging materials C # steam bars S coating applicator S release tester N liner width y N plant environment
Ý à 0 *
Customer Converting
N Noise à Crit ical Parameter C Controllable Parameter S SOP
Packaging/Shipping (UPM)
PC-4 Liner Remoisturization
PC-4 Silicone Drying/Curing
Process Map Example

Accounts Receivable and Invoicing Process Map (with data and rework)
Mail Invoice to Asiana
Approve Payment
Resolve Dispute
Re-Issue Invoice
S Invoice Document C Price C Quantity C Workscope
S Customer Address S Shipping Document S Postal Service (Asia) C Fedex
S Mail Box C Mail Checking Frequency N Mail Clerk C Queue Time
N Mail Clerk S Classification of Invoice by P.O #
S Receipt of Invoice C Inbox Location C Queue Time N Purchasing Section Manager
N Purchasing Section Manager S Original Quote Documentation S Invoice Documentation C Comparison of Quote & Invoice
Yes
No
Y
N Priority N Shipment Hold N AOG S Invoice Data N Purchasing Manager C Time to Create Voucher
N Accounting Rep S Payment Voucher S Database System
N Accounting Rep C Budget Allocation C Purchasing Influence S ATL’s Influence N Priority of Payment
N Finance Rep S Bank Notice C Budget Allocation S Accounts Payable
Invoice Sent Invoice Received Invoice Collected by Clerk Invoice Distributed to Sections
Invoice Received by Each Section
Acceptance DecisionPayment VoucherSystem Input
C Business Unit Involvement S Type of Dispute
(Price, Quantity,Workscope) N Purchasing Section Manager S Retrieval of Relevant Files S ATL Involvement C Time to Resolve Dispute C Communication
S Dispute Resolution Agreement S Express Mail
Dispute Resolved New Invoice
2 (13)7 (20)4 (24)

Documents

1.18 Process Map Rev RK 20080601