11. Flowcharts

The three most common types of flowchart

1. Spaghetti diagrams, they look like their name suggests. With spaghetti diagrams, you draw a continuous line from the start of the process through every step along the value stream to the end. In a non-lean environment, these diagrams often end up looking like a plate of spaghetti. 2. Process maps, use symbols to represent steps and machines with arrows indicating the flow of parts among them. Some process maps may include a few metrics and points of communication that occur within the process. These would be placed in a box in the corner of the chart, written on the arrows, or within the symbols themselves. 3. Value stream maps, use a more complex system of symbols, text boxes, metrics, and arrows. A value stream map is a diagram of every step involved in the material, process, and information flows needed to bring a product or service from order to delivery. Each type of flow chart may be used to create both current- and future-state diagrams of your manufacturing or transactional process. However, because of the varying amount of detail included for each, the resulting charts will be quite different.

Common Flowchart Mistakes?

1. Uneven flowchart symbol sizes: When possible, make all your flowchart symbols the same height and width. If that's not feasible, then consider at least making the symbol widths the same and varying the heights. 2. Uneven spacing between flowchart symbols: Try to maintain even spacing both horizontally and vertically between symbols. The one exception should be for Decision symbols. You should add extra spacing around these to accommodate branch labels. 3. Inconsistent flow direction: Overall a flowchart should have a consistent flow direction. It should be top-to-bottom or left-to-right or right-to-left. Try to avoid mixing top-to-bottom and left-to-right flows in the same flowchart. Multi-column and S-shaped flowcharts are fine too, as long as the flowchart is consistent. 4. Inconsistent branch direction: It's easier to follow the logic of a flowchart if the branching directions are consistent. For example, you could make the True conditions always flow out of the bottoms of Decision symbols and the False conditions flow out of the right sides of Decision symbols. 5. Long flow lines: If your flow lines are running from one edge of the flowchart to the other, it's better to use Connector nodes. Connector nodes are labeled circles that serve as jump points from one another. 6. Too many colors: There's nothing wrong with a nice, stylistic flowchart, but don't overdo it. You don't want the flowchart's message to get lost in a sea of visual noise. 7. Truncated descriptions: One of the biggest disadvantages of flowcharts is that they require concise process step descriptions. However, not all operations can be described tersely. In these cases, you should use a Callout, a footnote, or a separate document to go into more detail.

What is a flowchart?

A flow chart is a visual representation of the steps required to manufacture a product or to provide a service. Using special symbols, the team maps both the current and future state of the targeted process and creates a "big picture" view. Each step in the process is represented by different symbols' shapes which show how the process works. For instance, a rectangle represents a process step and contains a short description of the process step. The flow chart symbols are linked together with arrows showing the process flow direction. Common alternate names include: process flow chart, process map, process chart, business process model, process model, process flow diagram, work flow diagram, business flow diagram, or just flow diagram

How to create a flowchart?

Creating a process map chart is very simple and follows a logical process that requires 4 steps: 1. Start with determining the process boundaries in order to understand where the process flow starts and ends. 2. Determine the level of details to include. Flow charts can be as simple or as detailed as you need to make them. Ask yourself "what is the minimum level the detailed needed?" 3. Sequence and connect the steps. Use the common symbols review previously; and 4. Test the flow chart for completeness. Go, see and follow the process flow to validate the flow chart actually presents the current state. If the flow chart is designed to describe the future state, use simulations to validate your proposal.

Why use flowchart

Flowchart is used to 1. Allow team to identify the actual flow or sequence of events in a process. 2. It can also show problem areas, waste, redundancy, and where simplification may be possible for work flow management and continuous improvement of task related processes. 3. Flowchart also identify locations where additional data can be collected and investigated 4. It also shows connections with other related processes 5. And finally, flowchart is very useful as a training aid which allow learner to understand the complete process to related systems or tasks.

When to use flow charts?

Flowcharts will be a helpful tool throughout your Lean Six Sigma projects. They'll be created when you define the current state and when you develop your future state. For example, the flowchart is often used in the PLAN phase of the (PDCA) methodology as you clarify the problem in Step One, and also as you Develop countermeasures in Step Five. In DMAIC methodology, the flowchart is used to show the AS-IS STATE of the current process flow within the DEFINE stage, and can be used again to communicate the TOBE STATE of the enhanced process flow within the IMPROVE stage. This is also true for the DMADV methodology where flowcharts are usually used in the DEFINE and DESIGN stages.

What are common flowchart symbols?

These are the common process flowchart symbols. Each symbol represents each step in the process and contains a short description on the process step. 1. A oval or rounded rectangle shape refers to: A start or ending point in process 2. A rectangle shape refers to: An operation or action step 3. A diamond shape refers to : A decision point which could be a question or branch in the process 4. Finally, arrows are used to link the symbols together, showing the process flow direction