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

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.

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

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

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

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!

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”

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

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

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

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

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

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

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