These slides are part of the ESTIEM Lean Six Sigma Green Belt course which also includes 13hr of video by Gregory H. Watson. For more info about the ESTIEM Lean Six Sigma Green Belt course visit https://internal.estiem.org/leansixsigma

1. European Students of Industrial Engineering and Management
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Process mapping & Bottleneck identification
for publication
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2. European Students of Industrial Engineering and Management
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It’s Feedback time!
2
Persons giving feedback
Link to the feedback form
(can be found on Schoology and
WhatsApp)
Instructor to give feedback toPersons giving feedback
INSTRUCTOR 1
INSTRUCTOR 2

3. European Students of Industrial Engineering and Management
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What do you remember about DMAIC?
Project
Charter
SIPOC
EDA
VA vs.
NVA
DEFINE
Deployment
Diagram
Identifying the
Bottleneck
MEASURE
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4. European Students of Industrial Engineering and Management
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What will we talk about next?
Deployment
Diagram
Mapping the
different process
steps
Identifying the
Bottleneck
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5. European Students of Industrial Engineering and Management
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The output should be several post-its you can
move around ...
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6. European Students of Industrial Engineering and Management
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Three different symbols can be used – activities,
decisions, and control points
Activity DecisionControl
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7. European Students of Industrial Engineering and Management
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Simple illustration of the symbols
Cut the paper
in half
Pass?Measure
the length
Ship the
product
No
Yes
Cut the paper
in half
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8. European Students of Industrial Engineering and Management
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Time to work…
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9. European Students of Industrial Engineering and Management
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SPONSOR MESSAGE
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10. European Students of Industrial Engineering and Management
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Quiz time!
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11. European Students of Industrial Engineering and Management
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Question:
Why do you differentiate between regular
activities and the measuring activity?
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12. European Students of Industrial Engineering and Management
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Question:
Give a practical example of
a control and a decision point?
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13. European Students of Industrial Engineering and Management
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The Deployment Diagram
Deployment
Diagram
Mapping the
different process
steps
Identifying the
Bottleneck
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14. European Students of Industrial Engineering and Management
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What does “to deploy” mean
in this context?
=
How resources are distributed
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15. European Students of Industrial Engineering and Management
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Simple illustration of the symbols
Cut the paper
in half
Pass?Measure
the length
Ship the
product
No
Yes
Cut the paper
in half
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16. European Students of Industrial Engineering and Management
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What makes it a deployment diagram?
Cut the paper
in half
Pass
?
Measure
length
Ship the
product
No
Yes
Person 1
Person 2
Person 3
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17. European Students of Industrial Engineering and Management
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Time to work…
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18. European Students of Industrial Engineering and Management
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SPONSOR MESSAGE
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19. European Students of Industrial Engineering and Management
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Quiz time!
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20. European Students of Industrial Engineering and Management
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Question 1/3:
Why is it important to map the different
steps of the process?
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21. European Students of Industrial Engineering and Management
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Question 2/3:
What could be problematic in setting up
the deployment diagram?
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22. European Students of Industrial Engineering and Management
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Question 3/3:
How are SIPOC maps and deployment
diagrams linked to each other?
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23. European Students of Industrial Engineering and Management
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Identifying the Bottleneck
Deployment
Diagram
Mapping the
different process
steps
Identifying the
Bottleneck
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24. European Students of Industrial Engineering and Management
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First of all, some definitions…
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25. European Students of Industrial Engineering and Management
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What is the difference between
push and pull production?
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26. European Students of Industrial Engineering and Management
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Push = production is done towards the
individual targets (production plan),
can be produced to stock
Pull = production is started only when the
next process step demands a product
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27. European Students of Industrial Engineering and Management
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What are the problems with
the push production?
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28. European Students of Industrial Engineering and Management
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Push production can lead to waste by …
• Excess inventory (e.g. tied working
capital, inventory costs…)
• Hides inefficiencies in the process
• Increases the detection time of defects
• … … … …
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29. European Students of Industrial Engineering and Management
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The optimal state is often referred to as
having a good ”flow”.
What do we mean by the ”flow”
in a production line?
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30. European Students of Industrial Engineering and Management
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Flow = how the work progresses in the
process
Good flow = work progresses steadily
and predictably through the process
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31. European Students of Industrial Engineering and Management
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What do we mean by takt time?
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32. European Students of Industrial Engineering and Management
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Takt time = customer order rate, i.e.
(available time) / (number of orders)
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33. European Students of Industrial Engineering and Management
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What is the difference between lead time
and cycle time?
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34. European Students of Industrial Engineering and Management
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Throughput time = the time it takes to go
through the production
Cycle time = the time taken by one process step
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35. European Students of Industrial Engineering and Management
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0,
1,5
3,
4,5
6,
7,5
Step 1 Step 2 Step 3 Step 4 Step 5
Identify takt, cycle and lead time
Time (min)
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36. European Students of Industrial Engineering and Management
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0
1
2
3
4
5
6
7
Step 1 Step 2 Step 3 Step 4 Step 5
Takt time
Cycle Time
Time (min)
Identify takt, cycle and lead time
Waiting ? = Lead time
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37. European Students of Industrial Engineering and Management
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What do we mean by ”Bottleneck”?
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38. European Students of Industrial Engineering and Management
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What is the effect of the Bottleneck?
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39. European Students of Industrial Engineering and Management
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0,
1,5
3,
4,5
6,
7,5
Step 1 Step 2 Step 3 Step 4 Step 5
Takt time
What happens if you improve the step 3?
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40. European Students of Industrial Engineering and Management
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0,
1,5
3,
4,5
6,
7,5
Step 1 Step 2 Step 3 Step 4 Step 5
Takt time
How do we call the ”step 5”?
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41. European Students of Industrial Engineering and Management
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0,
1,8
3,5
5,3
7,
Step 1 Step 2 Step 3 Step 4 Step 5
Takt time
Where is the bottleneck now?
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42. European Students of Industrial Engineering and Management
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1 2 3 4 5 6 107 8 9 1112
Variation reveals new aspects! Which chart is
best for bottleneck identification?
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43. European Students of Industrial Engineering and Management
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Quiz time!
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44. European Students of Industrial Engineering and Management
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Question:
How do the following terms link together:
1) Lead time
2) Takt time
3) Cycle time
4) Bottleneck
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45. European Students of Industrial Engineering and Management
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Question:
Why is it important to pursue
good flow in a production line?
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46. European Students of Industrial Engineering and Management
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Time to work…
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47. European Students of Industrial Engineering and Management
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SPONSOR MESSAGE
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48. European Students of Industrial Engineering and Management
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How was the recording of the data?
What did you recognize?
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49. European Students of Industrial Engineering and Management
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Thank you for your
attention!
49

50. European Students of Industrial Engineering and Management
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It’s Feedback time!
50
Persons giving feedback
Link to the feedback form
(can be found on Schoology and
WhatsApp)
Instructor to give feedback toPersons giving feedback
INSTRUCTOR 1
INSTRUCTOR 2

51. European Students of Industrial Engineering and Management
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It’s Feedback time!
Feedback box
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52. European Students of Industrial Engineering and Management
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Usage license of the
materials
https://creativecommons.org/licenses/by-nc/4.0/legalcode
Contact leansixsigma@estiem.org
for commercial usage of the materials
Materials of the trainings have been created based on the materials provided by
ESTIEM Summer Academy Professor Gregory H. Watson