Flow Process Chart

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Continuous Improvement Toolkit

Flow Process Chart


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Flow Process Chart

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Hoshin Kanri


The Flow Process Chat is a symbolic representation

that illustrates the sequence of actions within a process.

It is commonly used when analyzing the steps in

a process to help identify and eliminate waste.

It records the steps of a process along a vertical line.

It is used to show the steps of a process using symbols

along with text.

- Process Flow Chart


A useful feature of the Flow Process Chart is that it can be drawn

up as the process is happening.

This will allow getting an accurate description of the process.

By watching and recording, a person for example can follow a

part, noting how and when it is produced, moved, checked and

stored.

This ensures that what actually happens gets recorded.

Later when analyzing the process, some steps become

obvious candidates for improvement, such as long

delays and non value adding activities.



Common Symbols:

Operation: Produce or process something.

Storage: Storing materials or other items.

Transport: Movement of people, materials or other items.

Delay: Idle time of people,

material or machinery.

Inspection: Checking of

items to ensure correct

quality or quantity.


Inspection

Transport

Delay

Storage

Operation

Decision

Rejection point


Three Types:

A man-type chart which shows the actions of a person.

A material-type chart which shows what happens to a product

or item.

An equipment-type chart which shows how a tool or other piece

of equipment is used.



Example –Egg Trays Production:


Store of waste paper

Convey to mixer

Pulping and mixing

Convey to forming machine

Drying

Forming (Moulding)

Inspecting & counting

Stacking

Packing

Convey to warehouse

Store at warehouse


Example – Supplier Invoice Processing:


Supplier invoice receive

Enter invoice into system

Match invoice, PO & receipt information

Authorize payment

Pay the supplier

10 minutes

15 minutes

60 minutes

Send for authorization 5 minutes

30 minutes


Example – How to Improve the Biscuit Production Process?


Mix put into molder

Biscuits molding

Biscuits to oven

Baking biscuits

Biscuits to inspection line

Cooling

Inspection for misshapes

Staking for packaging

Wrapping

Put into shipping boxes

Store at warehouse



Hidden Factors



An outsider?

Walk the process and understand it

Leadership & Management

Flow Process Chart