August 9, 2015

Lean Process Mapping Symbols

Resource: Process Mapping Symbols, Generic Start / Stop block., Generic Process step, Generic Decision step, Supplier Customer icon, General Process icon., Shared Process icon., Data Box icon., Cell icon, Inventory icon., Material Movement, Push material, Storage or Supermarket, Pull, First‐In‐First‐Out FIFO, Shipping, Production Control, Electronic Information, Electronic Information, Manual Information, Production Kanban, With drawl Kanban, Kaizen Burst, Timeline

Process Mapping Symbols

Generic Start / Stop block. Start begins with the start of the process and stops typically close to the next customer.

Generic Process step can be used to any process step step, represent step.

Generic Decision step, can be used to represent any process step

Supplier Customer icon. When in the pp / upper left, the usual starting point for material flow it represents the Supplier. The Customer is typically placed in the upper right and represents the end of the process flow.

General Process icon. It can represent an operation, machine or department, through which material flows. Typically, to avoid unwieldy mapping of every single processing step, it represents one department with a continuous, internal fixed flow path. In the case of assembly with several connected workstations, even if some WIP inventory accumulates between stations) machines (or stations), the entire line would show as a single box

Shared Process icon. A process operation, department or work‐center that other value stream families share. Estimate the number of operators required for the Value Stream being mapped, not the number of operators required for processing all products.

Data Box icon. Typically goes under process icon, information placed in a Data Box may include CT (Cycle Time) i.e. part to part time. C/O (Changeover Time), Uptime‐ percentage time that the machine is available for processing, Operation time i.e. number of shifts, and total minutes available for work.

Cell icon. Cells typically have multiple processes are integrated together. Most often used for limited family of similar products or a single product. Product moves from process step to process step in small pieces batches or single pieces.

Inventory icon. Represents inventory between two processes. It may also be used to storage for raw materials and finished goods.

Material Movement icons. The down arrow is used for incoming raw Value Stream material from suppliers to the receiving area. The upward arrow is used to show the movement of finished goods to the customers

Push material icon. It represents the “pushing” of material from one process to the next process. Push means that a process produces something regardless of the immediate needs of the downstream process.

Storage or Supermarket icon. Typically used as a kanban stock point. Like a supermarket, a small inventory is available and one or more downstream customers come to the supermarket to pick out what they need. The upstream work center or receiving then replenishes stocks as i d required. When continuous flow is impractical, and the upstream process must
operate in batch mode, a supermarket reduces over production and limits total inventory

Pull icon. Supermarkets connect to downstream processes with this Value Stream “Pull” icon that indicates physical removal..

FIFO icon.. This icon is used to represent processes which are connected with a First‐In‐First‐Out inventory system that limits input. (i e roller possible top or FIFO i.e. conveyor) Record the maximum inventory on Mapping bottom of icon.

Shipping icon. This icon is used to represent external shipping either from a supplier for incoming material or deliverable to a customer

Production Control icon. This box represents a central production  scheduling or control department, person or operation.

Electronic Information icon. This is used to represent electronic information flow such as electronic data interchange (EDI), the Internet,Intranets, LANs (local area network), WANs (wide area network), etc. Mapping You may indicate the frequency of information/data interchange, the type of media used ex. fax, phone, etc. and the type of data exchanged.

Manual Information icon. The manual flow of general information. This can come from face to face conversations, memos, and/or reports Frequency and other notes may be relevant

Production Kanban icon. This icon represents a card, device or signal that instructs a material handler to transfer parts from a supermarket to the receiving process. Although there are many such icons used, it may also be used to signal the up stream process to make more product.

With drawl Kanban icon. This icon represents a certain amount of stock or inventory has been used to signal that a replenishment may be needed.

Kaizen Burst icon. These icons are used to highlight improvement needs and plan kaizen workshops at specific processes that are critical to achieving the Future State Map of the value stream

Operator icon. Used to show where operator(s) are present. This maybe multiple copies of the icon or a number placed next to it to show when more than one are present.

Timeline icon. This is used to calculate the Value Added (VA) and Non‐ Value Added (NVA) time in the process.

 

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