1. High Level Process Mapping
Measure
I/O Map
© 2014 Ports America. All rights reserved.

2. Objectives Describe major process steps of a project
Develop a comprehensive list of inputs and outputs required for each step
Classify input variables as S, C, or N in the determination of controllable or noise factors
© 2014 Ports America. All rights reserved.

3. Remember SIPOC?
I/O Mapping takes a deeper dive in the middle section of the SIPOC
The I/O Map helps team analyze and classify process inputs and outputs
Inputs (X’s) and Outputs (Y’s) are the main emphasis

4. Definitions I = Input P = Process
Materials, resources and data required to execute your process
P = Process
Series of steps or activities that uses one or more kinds of inputs and changes them into an output that is of value to the customer
O = Output
Tangible products or services that result from the process and the metrics

5. Steps for Performing I/O Mapping
Identify all steps in the process
List key output variables at each step
List key input variables and classify process inputs as controllable or uncontrollable

6. 1. Identify the Process Steps
Start with the process steps that defines the start of your process and end of your process
Include all value-added and non value-added steps
Keep it simple: 4-6 step is ideal, 8-12 maximum
Process steps are actions, use verbs!

7. 2. Determine the Outputs For Each Step
Identify what the process step “produces”
Two types of outputs:
Process Deliverables: the actual output of the process
Business Measures: consequence of running the process; i.e., quality, delivery, or cost/productivity related
Outputs should be:
Measurable: use “bolt length”, not “correct bolts” or “bolt length on target”
Specific, not general: use “operator experience” or “analyst typing speed”, not just “operator” or “analyst”

8. 3. Determine the Inputs For Each Step
Identify what is put into the process step
Inputs should be specific, like outputs
Inputs generally fall into the ‘6 M’ categories (Man, Machine, Materials, Mother Nature, Measurement, and Methods)
Outputs from one step may become an Input to another
Classify the Inputs as (S), (C) or (N)
(S) Standard Operating Procedure
(C) Controllable
(N) Noise or Uncontrolled

9. Classification Types Defined
(S) Standardized inputs: Input variables under operating Procedure/ Policy or a detailed work instruction for running that process step
(C) Controllable inputs: Key X’s that are actively controlled and that can be changed to see the effect on the output (Y)
(N) Noise inputs: Input variables (X’s) that impact the output variables (Y’s) but are difficult, impossible or we choose not to control. i.e. – Environmental variables such as humidity or temperature

10. Discussion “Baking a Cake”: Identify inputs; classify as S, C, or N I
____________________________________
Prepare
__________________
____________________________________
Cook
__________________
____________________________________
Serve
__________________

11. Operations Example Surface Prep Prime Paint Dry Outputs Clean surface
Make minor repairs
Sand surface
Clean Surface
Inspect
Prime
Adjust air pressure
Load primer
Record primer lot
Prime surface
Paint
Check nozzle type
Inspect surface
Record paint lot
Paint surface
Dry
Set oven profile
Rework
Outputs
Clean surface
Surface finish
Prep time
Defect / repair count
Air pressure
Complete coverage
Prime time
Primer lot
Primer thickness
Paint time
Paint lot
Paint thickness
Dry paint
Dry time
Paint hardness
Inputs
Type
Surface contamination
Surface roughness
Chassis type
Sanding grit
Filler lot
Sander RPM
Nozzle type
Primer age
Ambient temp
Relative humidity N C
Paint age
Paint viscosity
Oven profile
Thermocouple calibration

12. Non-Ops Example Cross reference for P/N’s Order information
Plant loading information
Order worksheet form
Pricing algorithm
Information from customer
Greeting script
Answering procedure
Telephone system
Type
Outputs
Answer Phone
Greet customer
Determine P/N
Identify need date
Identify ship to address
Identify ship method
Enter Order Information
Input information
Print order confirmation
Determine ship date
Review order
Confirm Order
FAX confirmation to customer
Verify manufacturing receipt of order
Inputs
Order worksheet
Computer entry screens
Lead time information from mfg
Shipment method
Printed confirmation sheet
Production schedule
Customer contact info
Production contact info
Confirmation procedure N C
Prompt answer
Live body
Part number
Availability
Need date
Get Internal Information
Get internal P/N
Determine terms
Identify lead time
Complete order worksheet S
Customer number
Pricing
Order in computer
Correct info
Promise date
Order number
Printed confirmation
Time to Enter
Order confirmation to customer
Order to production

13. Exercise: I/O Process Mapping
Consider the process of making a great cup of ‘Cappuccino’ …
With your team, create an I/O Process Map
Identify all steps in the process
List key output variables at each step
List key input variables
Classify process inputs as controllable or uncontrollable

14. Review Describe major process steps of a project
Develop a comprehensive list of inputs and outputs required for each step
Classify input variables as S, C, or N in the determination of controllable or noise factors