metrics-based process mapping: part 1 of 3
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Metrics-Based Process Mapping Part 1 of 3
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Karen Martin, PrincipalKaren Martin & Associates
www.ksmartin.com
Mike Osterling, PresidentOsterling Consulting www.mosterling.com
Chapter 12 –Metrics-Based Process Mapping
(manual method)
Excel Tool for Archiving Completed Maps
Available from Productivity Press, Amazon, or any major bookseller
About Us
© 2010 Karen Martin & Associates 3
Metrics-Based Process Mapping:Three-Part Series
Part 1: Document the current statePart 2: Analyze the current state; design
and implement the future statePart 3: Document the improved process
© 2010 Karen Martin & Associates
The Work We Do:Degrees of Granularity
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Value Stream
Process Process Process
Step Step Step
Value Stream Map
Micro View
(Tactical)
Macro View
(Strategic)
Metrics-Based Process Map
© 2010 Karen Martin & Associates 5
Traditional Mapping Method:Process Flow Chart
Where’s the quality? Where’s the time?
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How do we know what to improve?
Traditional Swim Lane Process Maps
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What is a Metrics-Based Process Map?
A visual process analysis and design tool, which integrates: Functional orientation of traditional swim lane process maps Key Lean time and quality metrics
The office/service version of the standard work combination sheets often used to improve manufacturing processes.
Tool which highlights the disconnects / wastes / delays in a process Keeps the improvement focus properly directed
Serves as standard work for workforce training and process monitoring
Metrics-Based Process Mapping (MBPM)
© 2010 Karen Martin & Associates
When is the MBPM Used?
For current state analysis and future state design during an office/service-based Kaizen Event.
As a stand alone improvement tool. To avoid sub-optimizing, tie all improvements to a
strategic improvement plan such as a value stream map.
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© 2010 Karen Martin & Associates
Supplies Needed
36” wide white paperScissors & masking tape3 x 6” post-its (multiple colors)2 x 2” post-its (green and yellow)Sharpie markersA red or other brightly colored markerCalculators
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© 2010 Karen Martin & Associates
Mapping Preparation
Select a skilled facilitator. Scope the process being mapped – opt for narrow
current state focus so you can explore deeply and minimize variation.
Select a cross-functional team of no more than 10. Process workers (30-50% of the team) Upstream suppliers Downstream customers Outside eyes
Draw 6” wide swim lanes on the 36” paper. Pre-drawn lines – template available:
www.ksmartin.com/files/templates/MBPM_swimlanes.pdf Chalk line Manually draw
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Step 1: Label the map
Process Name Included/Excluded Conditions
Current State MBPM Date
Facilitator and/or Team Names
Step 2: Label the Swim Lanes with the Functions Involved in the Process
Process Name Included/Excluded Conditions
Current State MBPM Date
Facilitator and/or Team Names
Function A
Function B
Function C
Function D
Function E
Function F
Step1
Step2
Parallel Steps (concurrent activities)
Ticking clock
Step 3: Document all activities (steps) on 3 x 6” post-its; place sequentially
MBPM Post-it Conventions
Activity (Verb / Noun) Function that
performs the task
Step #
Step 4: Number the Activities
Note: For parallel activities, use alpha modifiers --e.g. 8A, 8B, etc.
# Staff (if relevant)
Barriers to Flow (if relevant)
• Batching
• Shared resources
• System downtime
• Etc.
PT (Process Time)
LT (Lead Time)% Complete &
Accurate
Step 5: Add Step-specific information
© 2010 Karen Martin & Associates 18
Key Lean Metrics: Time
Process time (PT) The time it takes to actually perform the work, if one is
able to work on it uninterrupted Includes task-specific doing, talking, and thinking aka “touch time,” work time, cycle time
Lead time (LT) The elapsed time from the time work is made available
until it’s completed and passed on to the next person or department in the chain
aka throughput time, turnaround time, elapsed time Includes Process Time
© 2010 Karen Martin & Associates
Lead Time vs. Process Time
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Lead Time
Work Received
Work passed to next step
Process Time
LT = PT + Waiting / Delays
© 2010 Karen Martin & Associates
Key Lean Metrics: Quality
%Complete and Accurate (%C&A) % time downstream customer can perform task without
having to “CAC” the incoming work: Correct information or material that was supplied Add information that should have been supplied Clarify information that should or could have been clear
This output metric is measured by the immediate downstream customer and all subsequent downstream customers.
If workers further downstream deem the output from a particular step to be less than 100%, multiply their assessment of quality with the previous assessments.
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© 2010 Karen Martin & Associates 21
Metrics-Based Process Mapping:Three-Part Series
Part 1: Document the current statePart 2: Analyze the current state; design
and implement the future statePart 3: Document the improved process
© 2010 Karen Martin & Associates 22
Karen Martin, Principal7770 Regents Road #635
San Diego, CA 92122858.677.6799
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For Further Questions