High Level Process Mapping

• Measure• I/O Map

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Objectives

• Describe major process steps of a project• Develop a comprehensive list of inputs and outputs required

for each step• Classify input variables as S, C, or N in the determination of

controllable or noise factors

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Remember SIPOC?

• I/O Mapping takes a deeper dive in the middle section of the SIPOC• The I/O Map helps team

analyze and classify process inputs and outputs• Inputs (X’s) and Outputs

(Y’s) are the main emphasis

Suppliers Inputs Process Outputs Customers

Customers

Returned product

Request for credit

Customer returns product; requests credit

Receiving initiates credit

process

Cust. Service and Tech

Service evaluate request

Accounting approves and registers credit

Customer service

processes credit and closes files

Credited amount on customer’s

account

Accurate computer records

Customers

Cust. Service

Tech Service

Accounting

SIPOC Analysis for Credit Voucher Process

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Definitions

I = Input • Materials, resources and data required to execute your process

P = Process• Series of steps or activities that uses one or more kinds of inputs

and changes them into an output that is of value to the customer

O = Output• Tangible products or services that result from the process and

the metrics

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Steps for Performing I/O Mapping

1. Identify all steps in the process2. List key output variables at each step3. List key input variables and classify process inputs as

controllable or uncontrollable

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1. Identify the Process Steps

• Start with the process steps that defines the start of your process and end of your process• Include all value-added and non value-added steps• Keep it simple: 4-6 step is ideal, 8-12 maximum• Process steps are actions, use verbs!

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2. Determine the Outputs For Each Step• Identify what the process step “produces”• Two types of outputs:• Process Deliverables: the actual output of the process• Business Measures: consequence of running the process; i.e., quality,

delivery, or cost/productivity related

• Outputs should be: • Measurable: use “bolt length”, not “correct bolts” or “bolt length on target”• Specific, not general: use “operator experience” or “analyst typing speed”,

not just “operator” or “analyst”

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3. Determine the Inputs For Each Step• Identify what is put into the process step• Inputs should be specific, like outputs• Inputs generally fall into the ‘6 M’ categories (Man, Machine,

Materials, Mother Nature, Measurement, and Methods)• Outputs from one step may become an Input to another• Classify the Inputs as (S), (C) or (N)• (S) Standard Operating Procedure• (C) Controllable• (N) Noise or Uncontrolled

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Classification Types Defined

• (S) Standardized inputs: Input variables under operating Procedure/ Policy or a detailed work instruction for running that process step

• (C) Controllable inputs: Key X’s that are actively controlled and that can be changed to see the effect on the output (Y)

• (N) Noise inputs: Input variables (X’s) that impact the output variables (Y’s) but are difficult, impossible or we choose not to control. i.e. – Environmental variables such as humidity or temperature

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Discussion

“Baking a Cake”: Identify inputs; classify as S, C, or N Prepare

Cook

Serve

____________________________________

____________________________________

____________________________________

__________________

__________________

__________________

I P O

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Operations Example

Surface Prep• Make minor

repairs • Sand surface• Clean Surface• Inspect

Prime• Adjust air pressure• Load primer• Record primer lot• Prime surface• Inspect

Paint• Adjust air pressure• Check nozzle type• Inspect surface• Record paint lot• Paint surface• Inspect

Dry• Set oven profile• Inspect surface• Rework

Outputs Outputs

• Clean surface

• Surface finish

• Prep time• Defect /

repair count

• Air pressure• Complete

coverage• Surface

finish• Prime time• Primer lot• Primer

thickness

• Air pressure• Complete

coverage• Surface

finish• Paint time• Paint lot• Paint

thickness

• Dry paint• Surface

finish• Dry time• Paint

hardness• Defect /

repair count

Inputs Type

• Surface contamination

• Surface roughness

• Chassis type• Sanding grit• Air pressure• Filler lot• Sander RPM

• Surface contamination

• Surface roughness

• Air pressure• Primer lot• Nozzle type• Primer age• Ambient temp• Relative

humidity

N

N

NCCNC

N

N

CNCNNN

Inputs Type• Surface

contamination• Surface

roughness• Air pressure• Paint lot• Nozzle type• Paint age• Ambient temp• Relative

humidity• Paint viscosity

• Chassis type• Air pressure• Ambient temp• Relative

humidity• Oven profile• Thermocouple

calibration• Paint thickness

N

N

CNCNNN

C

CNNN

CC

N

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Non-Ops Example

• Cross reference for P/N’s

• Order information• Plant loading

information• Order worksheet

form• Pricing algorithm

• Information from customer

• Greeting script• Answering

procedure• Telephone

system

Type Outputs

Answer Phone• Greet customer• Determine P/N• Identify need date• Identify ship to address• Identify ship method

Enter Order Information• Input information• Print order confirmation• Determine ship date• Review order

Confirm Order• FAX confirmation to

customer• Verify manufacturing

receipt of order

Inputs Type• Order

worksheet• Computer entry

screens• Lead time

information from mfg

• Shipment method

• Printed confirmation sheet

• Production schedule

• Customer contact info

• Production contact info

• Confirmation procedure

N

C

N

C

C

N

C

C

C

Inputs

C

CC

N

• Prompt answer

• Live body• Part number• Availability• Need date

Get Internal Information• Get internal P/N• Determine terms• Identify lead time• Complete order

worksheet

C

N

N

C

S

• Customer number

• Order worksheet

• Pricing

Outputs• Order in

computer• Correct info• Promise date• Order

number• Printed

confirmation• Time to Enter

• Order confirmation to customer

• Order to production

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Exercise: I/O Process Mapping

Consider the process of making a great cup of ‘Cappuccino’ …• With your team, create an I/O Process Map

1. Identify all steps in the process2. List key output variables at each step3. List key input variables4. Classify process inputs as controllable or uncontrollable

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Review

• Describe major process steps of a project• Develop a comprehensive list of inputs and outputs required

for each step• Classify input variables as S, C, or N in the determination of

controllable or noise factors