Continuous Improvement Toolkit Flow Process Chart Continuous Improvement Toolkit . www.citoolkit.com Managing Risk FMEA PDPC RAID Logs Pros and Cons Deciding & Selecting Break-even Analysis Planning & Project Management* Importance-Urgency Mapping RACI Matrix Stakeholder Analysis Cost Benefit Analysis PEST PERT/CPM Activity Diagram Force Field Analysis Fault Tree Analysis Pugh Matrix SWOT Roadmaps Project Charter Gantt Chart Voting Decision Tree Risk Assessment* TPN Analysis PDCA Control Planning Gap Analysis Matrix Diagram QFD Traffic Light Assessment Prioritization Matrix Hoshin Kanri Kaizen How-How Diagram Kano Analysis Lean Measures KPIs Paired Comparison Tree Diagram** Standard work Critical-to Tree OEE MSA Capability Indices RTY Descriptive Statistics Cost of Quality Cause and Effect Matrix Pareto Analysis Confidence Intervals Probability Distributions ANOVA Simulation TPM Understanding Cause & Effect Mistake Proofing Identifying & Implementing Solutions*** Pull Systems JIT Ergonomics Reliability Analysis Graphical Analysis Hypothesis Testing Design of Experiments Work Balancing Automation Scatter Plot Correlation Regression Bottleneck Analysis Understanding Run Charts Visual Management Multi-vari Charts Flow Performance Control Charts 5 Whys Chi-Square Test 5S Value Analysis Relationship Mapping* Benchmarking Fishbone Diagram SMED Waste Analysis Sampling TRIZ*** Focus groups Interviews Brainstorming Analogy Time Value Map Process Redesign SCAMPER*** Photography Check Sheets Nominal Group Technique Mind Mapping* IDEF0 Value Stream Mapping SIPOC Measles Charts Questionnaires Affinity Diagram Data Critical Incident Technique Collection Observations Attribute Analysis Lateral Thinking Visioning Creating Ideas** Flow Process Chart Process Mapping Flowcharting Service Blueprints Designing & Analyzing Processes Continuous Improvement Toolkit . www.citoolkit.com - Process Flow Chart     The Flow Process Chat is a symbolic representation that illustrates the sequence of actions within a process. It is commonly used when analyzing the steps in a process to help identify and eliminate waste. It records the steps of a process along a vertical line. It is used to show the steps of a process using symbols along with text. Continuous Improvement Toolkit . www.citoolkit.com - Process Flow Chart      A useful feature of the Flow Process Chart is that it can be drawn up as the process is happening. This will allow getting an accurate description of the process. By watching and recording, a person for example can follow a part, noting how and when it is produced, moved, checked and stored. This ensures that what actually happens gets recorded. Later when analyzing the process, some steps become obvious candidates for improvement, such as long delays and non value adding activities. Continuous Improvement Toolkit . www.citoolkit.com - Process Flow Chart Common Symbols:      Operation: Produce or process something. Storage: Storing materials or other items. Transport: Movement of people, materials or other items. Delay: Idle time of people, material or machinery. Operation Inspection: Checking of items to ensure correct Inspection quality or quantity. Decision Rejection point Continuous Improvement Toolkit . www.citoolkit.com Transport Delay Storage - Process Flow Chart Three Types:  A man-type chart which shows the actions of a person.  A material-type chart which shows what happens to a product or item.  An equipment-type chart which shows how a tool or other piece of equipment is used. Continuous Improvement Toolkit . www.citoolkit.com - Process Flow Chart Example –Egg Trays Production: Store of waste paper Inspecting & counting Convey to mixer Stacking Pulping and mixing Packing Convey to forming machine Convey to warehouse Forming (Moulding) Store at warehouse Drying Continuous Improvement Toolkit . www.citoolkit.com - Process Flow Chart Example – Supplier Invoice Processing: Supplier invoice receive 15 minutes Enter invoice into system 10 minutes Match invoice, PO & receipt information 5 minutes Send for authorization 60 minutes Authorize payment 30 minutes Pay the supplier Continuous Improvement Toolkit . www.citoolkit.com - Process Flow Chart Example – How to Improve the Biscuit Production Process? Mix put into molder Inspection for misshapes Biscuits molding Staking for packaging Biscuits to oven Wrapping Baking biscuits Put into shipping boxes Cooling Store at warehouse Biscuits to inspection line Continuous Improvement Toolkit . www.citoolkit.com - Process Flow Chart Hidden Factors Continuous Improvement Toolkit . www.citoolkit.com - Process Flow Chart An outsider? Walk the process and understand it Continuous Improvement Toolkit . www.citoolkit.com