Process Mapping - Process Flow and Interactions of Processes - ISO 9001

Helmut Jilling

Auditor / Consultant
Peter Fraser said:
...
Quoting the accepted definitions (which I believe are production line based, and so at the root of the problem!) you say "Inputs ... may include equipment". You say that a process "... transforms inputs into outputs". You say that "a cup" and "a spoon" are two of the inputs required to make a cup of coffee. So what do you use to make the second cup, now that the cup you used for the first customer has been "transformed" (into a pumpkin?)
...!


I think there is a simpler method to teach inputs and outputs. If we call all the items inputs, it gets too clumsy.

It is cleaner to define the spoon, coffemaker, measuring cup, recipe, etc. as the tools of the process. (This is where a turtle diagram would help make the discussion clearer).

The easier method is to ask what is the direct item(s) being taken from the previous process, upon which I will take further action.

The actual input would be the coffee beeans (an output of Purchasing) and water (is it distilled, tap, filtered, bottled, etc).

The actual output is the brewed coffee, which will probablt be packaged in a cup. The other output, invoice, used grounds, etc. are not "outputs. They are byproducts of the process.

I sometimes ask folks, what are you putting in the bucket which you are handing to the next process? What is the actual product of that process? Who do they "sell" it to (the next process)? This helps bring a simpler clarity to this exercise.
 

Peter Fraser

Trusted Information Resource
hjilling said:
I think there is a simpler method to teach inputs and outputs. If we call all the items inputs, it gets too clumsy.

It is cleaner to define the spoon, coffemaker, measuring cup, recipe, etc. as the tools of the process. (This is where a turtle diagram would help make the discussion clearer).

The easier method is to ask what is the direct item(s) being taken from the previous process, upon which I will take further action.

The actual input would be the coffee beeans (an output of Purchasing) and water (is it distilled, tap, filtered, bottled, etc).

The actual output is the brewed coffee, which will probablt be packaged in a cup. The other output, invoice, used grounds, etc. are not "outputs. They are byproducts of the process.

I sometimes ask folks, what are you putting in the bucket which you are handing to the next process? What is the actual product of that process? Who do they "sell" it to (the next process)? This helps bring a simpler clarity to this exercise.
Helmut

This also makes much more sense to me. It sounds as though you don't like the "transformation" definition either - or at least you don't try to justify it. It is interesting that your choice for the "input" is different from what I have seen others define as the input, ie the "customer need" or the "customer order".

I like the idea of "tools" ("resources"?), and of treating them as "things you need to have available for the process to work". Staff would also belong in this category (a product of the Recruitment and Training processes?).

But the bottom line is that I believe that all this would be unnecessary if we used a more intuitive definition, such as "a sequence of activities triggered by an event and designed to achieve an objective. It uses resources and is subject to influences." The "product" is the achieved objective. This works for a higher level process and also scales down to the individual task level. So the receipt of a customer order triggers the order processing process, and a New Customer form arriving in someone's Intray triggers the task to set up a new customer on the computer. Focussing on objectives is one of the key concepts which the ISO definition misses, and is vital for seeing how the business processes help to achieve the overall business strategy.

And we wouldn't need to debate what is an input, what is or isn't "transformed"...

Going back to the original theme of this thread - the way the processes interact is to do with how you make the required resources available, and how you manage the factors that can influence a process (such as compliance with external standards). I have never seen the point on drawing a picture to say that "we sell something then we make it then we check it then we deliver it then we invoice it" - everyone knows that!
 

Helmut Jilling

Auditor / Consultant
Peter, your thoughts are very insightful. However, I don't think I fully agree with every approach you sited.

The "process approach" under ISO should not be any different than process mapping without ISO. The principles are the same. I just think we make it too complicated, and lose sight of the purpose in the first place - ummm...to bring clarity to an activity (process).

Peter Fraser said:
Helmut

This also makes much more sense to me. It sounds as though you don't like the "transformation" definition either - or at least you don't try to justify it. It is interesting that your choice for the "input" is different from what I have seen others define as the input, ie the "customer need" or the "customer order".

I think subscribe to a "transformation" definition, though maybe we have different connotations of that word. A simpler definition is "A core process takes "something," and does something to it, and the resulting output has more value than before.

The coffee example takes coffee beans and water, and makes a tasty beverage which sells for $1.00. The next operation make take that nice basic beverage and add a bunch of extra silly ingredients, resulting (output) in a highly over developed designer beverage, and sell it to the customer for $4.50. If the customer has extra specifications, they have a more expensive product, but it meets their perceived needs.

When we discuss "core" or "Customer Oriented" processes, this relationship between inputs and outputs should be pretty clear and obvious. The rest of the details fall into the various Tools categories you mentioned.

However, when we discuss "non-core" or "Supporting" processes, like Training, Calibration, etc., the input/output conversation can be less clear. When working with a team of folks, I add another question to clarify the output concept.

For Training, the discussion would be as follows. OK, Training is an internal support process. In other words, Training is a service (product) provided b the HR Dept. OK, what is the result we expect to get? What is the product of that activity? What is the output? The answer is usually "trained, competent, people with proficient skills." OK, then "trained, competent, people with proficient skills" is the output of that Training process. Then it stands to reason the input was "UN-trained, NOT-competent, people with certain undeveloped skills."

I find groups of managers and regular folks have a much easier time developing it when this approach is clear.


I like the idea of "tools" ("resources"?), and of treating them as "things you need to have available for the process to work". Staff would also belong in this category (a product of the Recruitment and Training processes?).

Yes, but bear in mind, these tools probably were the result of an earlier process (Training, Purchasing, Process Designing, etc.)



But the bottom line is that I believe that all this would be unnecessary if we used a more intuitive definition, such as "a sequence of activities triggered by an event and designed to achieve an objective. It uses resources and is subject to influences." The "product" is the achieved objective. This works for a higher level process and also scales down to the individual task level. So the receipt of a customer order triggers the order processing process, and a New Customer form arriving in someone's Intray triggers the task to set up a new customer on the computer.

You may add and modify the "official" definition all you want internally. A good teacher always adds insight to the material, and tailors it to the needs of the student. But, don't lose the link to the original definition, because I don't think it is so far off. It just can be phrased better.

In the examples I sited above, the customer order "trigger" would be the input to the Sales/Contract Review/CSR Process (whatever the heck we are calling it nowadays). The output would be the processed order information on the form or ERP database. This information and order is the product we pay the Sales people for. And the effectiveness (cl 4.1.c) is judged by whether the information is complete and accurate, and in my opinion, whether they get enough of these transactions. Then, the next process - Engineering/APQP - takes this information and fashions a product and process to meet these needs/requirements.

It is very easy to "map" this just scribbling a half dozen circles on the whiteboard. The class sees the concept, then they begin to develop each one. All the rest of the activities tend to fall into the "Support Process" categories.

Focussing on objectives is one of the key concepts which the ISO definition misses, and is vital for seeing how the business processes help to achieve the overall business strategy.

No, not at all. in my view, ISO is very focused on effective results from each process. In other words, effective outputs from each process, which then become effective inputs for the next INTERNAL customer - the next process in the chain. The failure is that everyone steps right over 4.1.c and jumps right to 4.1.e. They measure "stuff (4.1.e)," when they haven't even defined and documented what "stuff" is important (4.1.c).

Imagine inspecting a part to a blueprint that does not define what the acceptance criteria shall be. Well, why do we evaluate (inspect) processes to criteria that has not been defined (4.1.c).


And we wouldn't need to debate what is an input, what is or isn't "transformed"...

I think my approach reduces much of this to a comfortable discussion.


Going back to the original theme of this thread - the way the processes interact is to do with how you make the required resources available, and how you manage the factors that can influence a process (such as compliance with external standards). I have never seen the point on drawing a picture to say that "we sell something then we make it then we check it then we deliver it then we invoice it" - everyone knows that!


Oh, contraire, my friend. Everyone THINKS they know this, but they only know it in part! And the parts they don't know as clearly as they thought, costs us millions of dollars, euros, etc.

The magic of the Process Approach is when we take what everyone "knows," and we plug it into maps, all sorts of small cracks and gaps appear. If we do this well, and give it its due, we see where internal suppliers have a completely different opinion of what their product is than their internal customer's perception. And we see where internal customer's are judging the effectiveness of a process or output completely differently than the supplier did. It is in seeing these gaps and glitches, that we are able to connect the wires. This proper review allows an alignment and optimizing that can supercharge a company. I find this is a 12-36 month exercise of evolution, depending on the skills of the people leading the effort. It is also this exercise that makes a good consultant worth his weight in gold...
 
G

Greg B

Peter Fraser said:
"a sequence of activities triggered by an event and designed to achieve an objective. It uses resources and is subject to influences." The "product" is the achieved objective.

Mate I love IT!!!!! Great explanation:applause:

...I also think Helmut might be over complicating the issue about my coffee process. The aim of the lesson is to keep it simple as I aim at the lowest common denominator "The operator". They (IMO) don't really care about the flowery words and phrases they want to know what to do and how it interacts. Many of OUR processes are merely steps between other processes and in most the operator doesn't see an order, a customer or a finished product (read, Final product). So while my lesson, as it stands, works very well for MY company it would need to be structured differently to someone that made cct boards, isntalled dashboards, manufactured matchsticks or whatever but hopefully I get the concept across. The sad thing is that while we discuss this others, in most cases, will read only this page and not understand what we are talking about. So for those not familiar or can't backpage here is my presentation...Process mapping 101 :D
 
G

Greg B

hjilling said:
The magic of the Process Approach is when we take what everyone "knows," and we plug it into maps, all sorts of small cracks and gaps appear. If we do this well, and give it its due, we see where internal suppliers have a completely different opinion of what their product is than their internal customer's perception. And we see where internal customer's are judging the effectiveness of a process or output completely differently than the supplier did. It is in seeing these gaps and glitches, that we are able to connect the wires. This proper review allows an alignment and optimizing that can supercharge a company. I find this is a 12-36 month exercise of evolution, depending on the skills of the people leading the effort. It is also this exercise that makes a good consultant worth his weight in gold...
:applause:
This is exactly why I have people from different areas in each class. We need to find the gaps between the processes. I usually have people up and down stream of a main process (including ancillary process' such as supply, maintenance and even accounts) and after the lesson we discuss how everything interacts. It is valuable lesson and a real eyeopener to most.
 

Peter Fraser

Trusted Information Resource
Greg B said:
This is exactly why I have people from different areas in each class. We need to find the gaps between the processes. I usually have people up and down stream of a main process (including ancillary process' such as supply, maintenance and even accounts) and after the lesson we discuss how everything interacts. It is valuable lesson and a real eyeopener to most.

So I reckon that we agree (?!) - what is important is for folk to understand why they are doing something, how it fits into the overall plan, what else needs to happen for them to achieve success, and to be able to describe it all clearly and concisely.

And ... it is surprisingly difficult for many people to see how activities all fit together, but using simple examples and simple terminology to focus on the key steps makes life easier for everyone.

So why is it such a struggle?!
 

Helmut Jilling

Auditor / Consultant
Peter Fraser said:
So I reckon that we agree (?!) - what is important is for folk to understand why they are doing something, how it fits into the overall plan, what else needs to happen for them to achieve success, and to be able to describe it all clearly and concisely.

And ... it is surprisingly difficult for many people to see how activities all fit together, but using simple examples and simple terminology to focus on the key steps makes life easier for everyone.

So why is it such a struggle?!


Because

1. it takes someone who clearly understands how this works to lead the exercise.

2. And, it takes the clear support of Top Management to participate and drive the process to ensure it is completed at all levels.

3. And finally, management then must take the results and carefully build continual improvement based on the resulting information.

This takes understanding, time, committment and leadership...
 
J

juliusmcl

Your process map is in a microview.First start with a bussiness process map, then a process map( for example purchasing,QA,Manufacturing,Warehousing,and distribution process), then in the warehouse process you have the receiving,staging, issuance procedure after that if it still needs further explanation come up with a work instruction.
 

Colin

Quite Involved in Discussions
I just thought I would throw in another example for your comments. This is the 'top level' process map I have put in a quality manual for a client. I am trying to show a brief overview of their main (core) processes plus the fact that there are other processes which impact on the core processes.

I have more detailed flowcharts for many of the boxes on this map which serve as procedures for how the activity is controlled.
 

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