Continuous Improvement Toolkit

Continuous Improvement Toolkit
Flow Process Chart
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Managing
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FMEA
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Field
Analysis
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Implementing
Solutions***
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Charts
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Flow Process Chart Process Mapping
Flowcharting
Service Blueprints
Designing & Analyzing Processes
Continuous Improvement Toolkit . www.citoolkit.com
- Process Flow Chart
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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
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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:
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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
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- Process Flow Chart
An outsider?
Walk the process and understand it
Continuous Improvement Toolkit . www.citoolkit.com