Page 272 - Lean six sigma demystified

250 Lean Six Sigma DemystifieD

A process control system of flowcharts, control charts, and/or histograms can
help you monitor and maintain your new level of performance. Process control
systems consist of
1. The system—suppliers, inputs, process, and outputs
2. Charts of performance—control charts and histograms

3. Corrective actions—changes to the people, process, machines, materials,
measurement, and environment—to respond to out of control conditions

4. Rework—to fix defects in finished products

Process Flowchart

Once you’ve made an improvement, it might be a good time to develop a pro-
cess flowchart or value stream map of the process. The simplified acronym for
a process is RADIO,
1. Repetitive—hourly, daily, weekly, monthly
2. Actions—step-by-step tasks and activities

3. Definable—observable and documentable (flowchart)
4. Inputs—measurable inputs (control charts)
5. Outcomes—measurable outputs (control charts)

Most processes can be diagrammed with four basic symbols.

• Start/End box
• Activity box
• Decision diamond
• Connecting arrow

Additional symbols can be added as required.
Creating a flowchart from scratch is like putting together a puzzle: It’s best
to get all the pieces out on the table and then try to put them in order. To do
so requires flexibility and that flexibility comes from using Post-it notes.
“Swim lanes” flowcharts (Figs. 8-1 and 8-2) extend the flow-charting tech-
nique to show “who does what” and the macrosteps of the process.
Guidelines for constructing process flow charts include

• Start with identifying customer needs and end with satisfying them.
• Separate the process into areas of responsibility.