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การท า Process Mapping เพอสรางแผนทกระบวนการและเพมพนประสทธภาพงาน
30/08/2021
Copyright © 2019 BSI. All rights reserved 1
By
British Standard Institute (BSI)
Copyright © 2018 BSI. All rights reserved.3
The business process
Supplier(s) Customer(s)
Inputs Outputs
นยามของค าวา กระบวนการ (Process)
'ชดของกจกรรมทสมพนธกนหรอโตตอบทใชอนพตเพอสงมอบผลลพธทตงใจไว'
Copyright © 2018 BSI. All rights reserved.4
การท าแผนทกระบวนการคออะไร?
แผนผงกระบวนการเปนเครองมอทแสดงใหเหนอยางชดเจนวาขนตอนการท างานเปนอยางไร
ประเดนส าคญ มกจะประกอบดวย:• Inputs
• Outputs
• Activity steps
• Decision points
• Functions
Copyright © 2018 BSI. All rights reserved.5
การท าแผนทกระบวนการคออะไร?
มนบอกผอานวา:
อะไร?
ทไหน?
เมอไหร?
ใคร?
อยางไร?
Copyright © 2018 BSI. All rights reserved.7
วตถประสงคของการท าแผนทกระบวนการ
วตถประสงคของการท าแผนทกระบวนการคอการ
ปรบปรงความเขาใจ
CLARITY
Copyright © 2018 BSI. All rights reserved.8
ปรบปรงการมสวนรวมของพนกงานในการสรางแผนผงกระบวนการ
ใชเปนการแสดงภาพเพอใหเขาใจไดงาย
ประหยดเวลาและลดความซบซอนของโครงการ
ปรบปรงความเขาใจของกระบวนการ
ประโยชนของการท าแผนทกระบวนการ
การท าแผนทกระบวนการ:
Copyright © 2018 BSI. All rights reserved.10
เครองมอนมรปแบบใดบาง?
High-level mapping tools
• Tree diagram
Functional mapping tools
• Flow diagram
• Top-down flow diagram
• Deployment flow diagram
• Detailed flow diagram
• Cross functional map
• Swim lane technique
• Tabular method
Operational mapping tools
• Spaghetti diagram • Value stream map
• SIPOC
Copyright © 2018 BSI. All rights reserved.11
ระดบของการท าแผนทกระบวนการ
Copyright © 2018 BSI. All rights reserved.
Business development
Sales Underwriting Contracting Client service
Terms
Documents
Negotiate
Close
Client
Business process
(strategic)
Business processes
Core functional
departments
Sub-process
(external) Clients(internal) CustomerService department
ProceduresTasks
High-level process map
Underwriters
Detailed sub-process map
Detailed sub-
process
Supplier
Copyright © 2018 BSI. All rights reserved.13
SIPOC
SIPOC Diagram[Suppliers – Inputs – Process – Outputs – Customers]
Suppliers
Inputs Process Outputs
Customers
Copyright © 2018 BSI. All rights reserved.14
ตวอยาง SIPOC
Suppliers Inputs Process Outputs Customer
Recruiting New staff Requesting department
Personal record file
Application letters
Company budget
Job applicants
Requisition request
Requesting department
Finance department
1. Review request
2. Advertise position
3. Screen applicants
4. Interview candidates
5. Process employment letter
6. Orientate new staff
Company policy
Management
Employment letter
New staff
HR department
Payroll instruction
Finance department
Orientation program
New staff
Copyright © 2018 BSI. All rights reserved.16
ความสมพนธระหวาง functional maps
Foundry
Machining
Assembling
Testing
Prepare material
Load fixture
Set up
Operate machine
Stop machine
Unload fixture
Unload material
Level 1 process map
Level 2 process map
Level 3 process map
Y
N
Copyright © 2018 BSI. All rights reserved.
Copyright © 2018 BSI. All rights reserved.17
Operation
Movement or Transportation
Inspection
Delay
Storage
Document
Databases
A A Connector
Arrows (flow of inputs or outputs)
Boundary (start / end) Decision
การใชสญลกษณใน Process mapping (for swim-lane and
detailed flow diagrams)
Copyright © 2018 BSI. All rights reserved.18
Top-down flow diagram – ตวอยาง
Design technical architecture
System standard design
Produce technical
specification
System prototype
development
Develop & test software modules
Technical documentation
Performance testing
User acceptance testing
System designSystem
development
Project planning
Project execution
Project control
Project management
Train users
Convert & migrate data
Deploy system
System implementation
Copyright © 2018 BSI. All rights reserved.19
Swim-Lane Technique: ตวอยาง 1
Customer
Sales officer
Repair technician
Request work
Generate work order
Receive work order
Get spare parts
Replace parts
Sign work order
Account clerk
Generate invoice
Make payment
Receive work order
Work order
Work order Invoice
Copyright © 2018 BSI. All rights reserved.21
Current state map
= 184 sec.
500 ft coils
2 Shifts
Tray= 20 pieces
PRODUCTION CONTROL
MRP
I
S.WELD #1
S.WELD #2
ASSEMBLY #1
ASSEMBLY #2
Staging
SHIPPING
Michigan Steel co.
State Street
Assembly
18,400 pcs/mo
-12,400 “L”-6,400 “R”
200 T
STAMPING
C/T = 1 second
C/O = 1 hour
Uptime =
85%27,000
sec.avail.EPE = 2 weeks
C/T = 38 seconds
C/O = 10 minutes
Uptime = 100%
2 shifts
27,000 sec.avail.
C/T = 45 seconds
C/O = 10 minutes
Uptime = 80%
2 shifts
27,000 sec.avail.
C/T = 61 seconds
C/O =
Uptime = 100%
2 shifts
27,000 sec.avail.
C/T = 39 seconds
C/O =
Uptime = 100%
2 shifts
27,000 sec.avail.
5 days
1 second
7.6 days 38 seconds
1.8 days
45 seconds
2.6 days
61 seconds
2 days
39 seconds
4.5 days
Production lead time
= 23.5 days
ValueAddedtime
Daily
ship schedule
Weekly schedule
6-week
forecast
Weekl
y fax
90/60/30 day
forecasts
Daily
order
Tuesday
+ Thursda
y
1x daily
Coils5 days
4600 L
2400 R1100 L600 R
1600 L850 R
1200 L640 R
2700 L1440 R
I I I I I
Copyright © 2018 BSI. All rights reserved.22
Value stream mapping icons
FINISHED GOODS
TO CUSTOMER
IINVENTORY
O X O X
LOAD LEVELING BOX
PROCESS
OPERATOR
SUPERMARKET
C/T = 45
sec
C/O = 30
min
3 Shifts
2% ScrapDATA BOX
ELEVATOR PICKING CART TRUCK
WITHDRAWA
L KANBAN
PRODUCTIO
N KANBAN
CHANGEOVER
KAIZEN
LIGHTNING
BURST
AIR FREIGHT SEA FREIGHT
MANUAL
INFO
Weekly
Schedule
PRODUCTION
SCHEDULE
MATERIAL PUSH
TIMELINE
KANBAN
POST
SUPPLIER/CUSTOME
R
Rework flow
Red dotted
Electronic information
First in first out
Withdrawal (pull)
Fork lift
Copyright © 2018 BSI. All rights reserved.23
State StreetAssembly
Icon:
18,400 pcs/mo- 12,000 LH- 6,400 RH
Tray = 20 pcs2 shifts
920 pcs/day
เรมทลกคากอนเสมอ
•State Street Assembly Co.
•18,400 pieces per month
•12,000 Type LH
•6,400 Type RH
•20 day month
•20 units per tray
•Operates on two shifts
•1 truck per day
•18,400 / 20 = 920/day
Customer requirements:
Copyright © 2018 BSI. All rights reserved.24
แผนทแสดงสถานะปจจบน
SHIPPINGI
2700 L1440 R
Staging
1xDaily
State StreetAssembly
18,400 pcs/mo
-12,000 LH-6,400 RHTray = 20
pcs2 shifts
920 pcs/day
Copyright © 2018 BSI. All rights reserved.25
• C/T (cycle time)
• C/O (changeover time)
• Uptime (on-demand machine time)
• EPE (every production every)
• Number of operators (dedicated)
• Available working time (minus breaks)
• Etc.
รวบรวมขอมลในกระบวนการ
Copyright © 2018 BSI. All rights reserved.26
Assembly #2
ACME stamping process
•2 part numbers
•1 operator
•2 shifts
•No setups
•39 sec. cycle time
•100% uptime
•2 - 10 minute breaks
•Inventory:
•1200 LH
•640 RH
C/T = 39 secondsC/O = 0
Uptime = 100%2 Shifts
27,600 sec/shift
1200 L640 R
IASSEMBLY #2
1
Copyright © 2018 BSI. All rights reserved.27
แผนทแสดงสถานะปจจบน
ASSEMBLY #2
1
C/T = 39 secondsC/O = 0
Uptime = 100%2 Shifts
27,600 sec/shift
I
1200 L640 R
SHIPPINGI
2700 L1440 R
Staging
1xDaily
State StreetAssembly
18,400 pcs/mo-12,000 LH-6,400 RH
Tray = 20 pcs2 shifts
920 pcs/day
Copyright © 2018 BSI. All rights reserved.28
Tuesday andThursday
MichiganSteel Co.
500 ft. coils
• Michigan Steel Co:
• 1 truck on Tuesday
• 1 truck on Thursday
• 500 foot coils
เพมซพพลายเออร
Copyright © 2018 BSI. All rights reserved.29
แผนทแสดงสถานะปจจบน
SHIPPING
C/T = 61 secondsC/O = 0
Uptime = 100%2 Shifts
27,600 sec/shift
Staging
MichiganSteel Co.
500 ft. coils
Tuesday. +Thursday
This is thematerial flow
INdoor
Door to door value stream
OUTdoor
State StreetAssembly
18,400 pcs/mo- 12,000 LH- 6,400 RH
Tray = 20 pcs2 shifts
920 pcs/day
1xdaily
IASSEMBLY #2
1
C/T = 39 secondsC/O = 0
Uptime = 100%2 Shifts
27,600 sec/shift
I
1200 L640 R
ASSEMBLY #1
1
S. WELD #2
1
C/T = 45 secondsC/O = 10 minutes
Uptime = 80%2 Shifts
27,600 sec/shift
1100 L600 R
1600 L850 R
IS. WELD #1
4600 L2400 R 1
C/T = 38 secondsC/O = 10 minutesUptime = 100%
2 Shifts27,600 sec/shift
ISTAMPING
I
Coils5 days
C/T = 1 secondsC/O = 1 hour
Uptime = 85%27,600 sec./shiftEPE = 2 weeks
200 T
STAMPING I
2700 L1440 R
Copyright © 2018 BSI. All rights reserved.30
สถานะปจจบน ระบโอกาสในการปรบปรง
= 184 sec.
500 ft coils
2 Shifts
Tray= 20 pieces
PRODUCTION CONTROL
MRP
I
S.WELD #1
S.WELD #2
ASSEMBLY #1
ASSEMBLY #2
Staging
SHIPPING
Michigan steel co.
State Street
Assembly
18,400 pcs/mo
-12,400 “L”-6,400 “R”
200 T
STAMPING
C/T = 1 second
C/O = 1 hour
Uptime = 85%
27,000 sec.avail.EPE = 2 weeks
C/T = 38 seconds
C/O = 10 minutes
Uptime = 100%
2 shifts
27,000 sec.avail.
C/T = 45 seconds
C/O = 10 minutes
Uptime = 80%
2 shifts
27,000 sec.avail.
C/T = 61 seconds
C/O =
Uptime = 100%
2 shifts
27,000 sec.avail.
C/T = 39 seconds
C/O =
Uptime = 100%
2 shifts
27,000 sec.avail.
5 days
1 second
7.6 days 38 seconds
1.8 days
45 seconds
2.6 days
61 seconds
2 days
39 seconds
4.5 days
Production lead time
= 23.5 days
ValueAddedtime
Daily
ship schedule
Weekly schedule
6-week
forecast
Weekl
y fax
90/60/30 day
forecasts
Daily
order
Tuesday
+ Thursda
y
1x daily
Coils5 days
4600 L2400 R
1100 L600 R
1600 L850 R
1200 L640 R
2700 L1440 R
I I I I I
Over processing
Waiting
Inventory Inventory
Waiting
Long lead time
Copyright © 2018 BSI. All rights reserved.31
ตองท าอะไรตอไปหลงจากการท าแผนท?
▪ Test (adequacy check)
▪ Validate
▪ Evaluate
Copyright © 2018 BSI. All rights reserved.33
การตรวจสอบแผนผงกระบวนการ
Walk the process again
Ask questions:
What happens if…?
What could go wrong?
Who?
How?
When?
Update the map
Copyright © 2018 BSI. All rights reserved.35
กระบวนการปรบปรง ไดแก:
• ขจดกระบวนการทงหมดส าหรบกระบวนการยอยทไมจ าเปน
• ขนตอนกจกรรมแบบแมนนวลอตโนมต
• รวมขนตอน
• องคประกอบการเอาทซอรสของกระบวนการ
• การเปลยนต าแหนงทท าขนตอนหรอคนด าเนนการ• การเปลยนแปลงหรอปรบเปลยนวธการด าเนนการตามขนตอนของกจกรรม
การพฒนากระบวนการสความเปนเลศ
Copyright © 2018 BSI. All rights reserved.37
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