ABB Basic Quality Tools Series

Process Mapping
Document the sequence of events in any process for
a product or service.

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 Process Mapping - Content
What is it for?
Visually documenting the sequence of events required to produce an No judgement or
criticism
Quantity more

specific outcome. than quality

Let ideas follow
one another

Ensures there is a thorough understanding of the process and Combine and

modify ideas

activities.
Where could I use it?
To document and standardize a process.
Use it in teams, to create shared understanding and build teamwork.

How do I use it?

Identify the output generated by the process.
Determine the level of detail for mapping of activity.
Follow the inputs as they are processed, recording each activity.
Identify activities that generate COPQ or waste.
Verify accuracy of map with individuals involved in the process.
Identify opportunities for removal of waste or actions which increase
variation in the outputs.

Risks and how to avoid them

Example

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 Process Mapping - What is it for?
Uses of this tool:
Process mapping is used to create a visual diagram of the sequential flow of material and manpower
to produce a specific output.
Associated with this activity is the establishment of a standard method for a process.

Expected Benefits:
Each step in the process is identified and agreed to by the improvement team, this promotes a
consistent understanding of the current situation.
Actions that create or support waste, COPQ, or non-value adding activity can be identified and
targeted for improvement.

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 Process Mapping - Where could I use it?
Background:
Many activities are not defined or have a
standard way of working.
Where multiple people perform the same
task, there may be variations in how the task
is performed.
Process maps can be scaled to provide the
level of detail necessary to analyze the
process and provide an understanding of the
activities.
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Uses:
Document the flow of material in the creation of a
product.
Understand the sequence of actions taken in a
process.
Communicate the steps to be followed in the
execution of a procedure.
Evaluate an activity for waste or COPQ.
Document the future method for a process
following an improvement project.
 Process Mapping - How do I use it?
Procedure and Guidance Notes:
Identify the outcome of the process. Consider the extent of your ability to change a
Define the
Determine the starting point, i.e. what are the inputs to the process. process and keep the mapping within your
process teams scope of authority.
Decide if supporting activities are to be included in the map.
boundaries

Understand purpose of the map. Some map templates require extensive

Determine the Select template that supports recording and display of activities and collection of data and may not be a good use of
type of map data. your teams time and resources.

Walk the process interviewing those involved in the activities.
Observe and
Record the information that you observe times, quantities,
record the equipment, physical layout, personnel, quality, procedures, etc.
process Understand the inputs, outputs and controls for each step.
Information that you record in this step will be
used to create the diagram that represents the
process, take care to fully understand what is
happening.

Using the template and symbols, transfer the information that you
Diagram the
collected in the observations onto the process map.
process on the Create linkages between activities to show relationships.
map template
Discuss the map with personnel involved in the process, identify any
areas that do not reflect the actual way work is performed.
Verify the map Walk the process using the new map to validate that it accurately
represents the actions.
This step may take more than one iteration as
you refine the picture of the activities and their
relationships.
Accuracy to the actual way of working is
important in understanding sources of COPQ,
waste and variation. Take care not to assume
that actions are taken or procedures are true.

Working with the diagram, look for areas where the work flow is not Inventory can be a sign of inefficiency, look for
Identify areas of smooth or there are unclear expectations. waste in all forms. Quality levels will also reflect
opportunity Identify situations where agreement was not reached on how the work situations where the requirements are not
was performed. clearly understood.

Working with the team, create a map of the desired process. Remove This may require the assistance of process
Create a to-be activities that do not add value or create variation in the process. experts. Use any resources available to the
map Use the to-be map as the basis for standardizing the work in a more team to eliminate wasteful activities.
efficient process.

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 Process Mapping - Risks and how to avoid them
Risks :
Too high level for adequate understanding of the process.
Too much detail is trying to be recorded and therefore it
increases the time and effort to document the process.
Type of map can impact the ease of
evaluation/understanding of the process.
Map does not portray the actual current situation.
Activities are not correctly identified, leading to wrong
conclusions.
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Steps to avoid them :
Decide in the beginning the level of detail necessary to
provide data for your improvement project.
Evaluate the different types of maps and which will best
meet your needs: Value Stream Maps, Swim-lane map,
Flow chart, Cross-functional map
Involve personnel who are performing the work in the
creation of the map. Validate the accuracy by walking
the process and checking that all is recorded.
Use the appropriate symbols for the style of map
chosen. Verify that you understand the reason for
activities before you assign a work classification.
 Process Mapping - Example
7. Create To-Be Map
1. Define Process Boundaries
Construction Process from
Estimate to Invoice

2. Select type of Process Map

Use Swim lane to which
departments are involved
6. Identify Opportunities

3. Observe, Record Process

5. Verify the Map

4. Diagram the Process

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