Process mapping is a simple, effective tool that is used to map the various steps of a process. It identifies bottlenecks. The process can pinpoint the root cause of deficiencies.
In every rapid cycle improvement activity, present state maps should be prepared.
Then an exercise in developing a future state maps, detailing the target goals for the process, can focus the team on specific areas and the root cause of any deficiencies.
There are four steps in process mapping:
- Process identification. Understanding all the steps in the process.
- Information Gathering. This should be done on a gemba walk, gathering and documenting the information by observation.
- Process Mapping. The actual drawing of the process Mao.
- Analysis. Using the LEAN tools to identify and eliminate the root cause of the deficiency.
Once the observations have been completed, a high-level process map can be developed. This is a visual representation of each individual step in the process and a key in understanding the present state of the process.
The best way to construct a process map is to use a whiteboard and Post-It notes. Write each activity on an individual Post-It note in the square orientation. Lay them out in a logical sequence, using a small rectangular post it to indicate the next step. When you come to a decision point, use the Post-It note as a diamond shape. Decision points offer several options. Use the small post it to indicate the option and continue the process along that direction. This must be done for every option to it’s conclusion.
Using these simple tools, based on your observations you can quickly develop the process map. The advantage of using this method is that changes can be made easily. Once the map has been developed, transfer it to the back of the A3 so you have a permanent record.