Standard Operating Procedure: Developing and Explaining a Flow Process Chart

Introduction

A Flow Process Chart is a fundamental industrial engineering and operations management tool used to document, analyze, and optimize a sequence of activities. Unlike a standard flowchart, a Flow Process Chart focuses on the movement of people, materials, or information, categorizing each step into standardized symbols: Operation, Transportation, Inspection, Delay, and Storage. This SOP provides a structured methodology for creating and presenting these charts to stakeholders to facilitate process improvement, identify bottlenecks, and eliminate non-value-added activities.

Phase 1: Data Collection and Observation

• Select the process scope: Clearly define the starting and ending points of the operation.
• Identify the subject: Specify whether the chart tracks a person, a material, or a specific document.
• Conduct a "Gemba" walk: Observe the actual process in real-time. Do not rely on historical documentation, as actual practices often deviate from written procedures.
• Record the raw sequence: Document every step chronologically. Capture details such as the distance traveled (in feet/meters) and the time taken (in seconds/minutes) for each step.

Phase 2: Classification and Charting

• Apply the standard ASME symbols:
  • Operation (O): Significant change to the item/information.
  • Transportation (->): Movement of the item from one location to another.
  • Inspection (☐): Checking for quality, quantity, or accuracy.
  • Delay (D): The item is waiting for the next step (e.g., sitting on a desk).
  • Storage (▽): Controlled storage where the item requires authorization to be moved.
• Draft the flow: Map the recorded steps into the grid format, ensuring that the distance and time columns are aligned with each activity.
• Calculate totals: Sum the total number of operations, transportations, inspections, delays, and storages. Calculate the total cycle time and total distance traveled.

Phase 3: Analysis and Presentation

• Apply the ECRS methodology:
  • Eliminate: Can any step be removed entirely?
  • Combine: Can two steps be performed simultaneously?
  • Rearrange: Can the sequence be changed to improve efficiency?
  • Simplify: Can the step be made easier or less costly?
• Explain the "As-Is" vs. "To-Be": Present the current process flow alongside the proposed improved version to clearly visualize the efficiency gains.
• Facilitate stakeholder feedback: Walk the process owners through the chart, highlighting where bottlenecks (Delays) and redundant movements (Transportations) were identified.

Pro Tips & Pitfalls

• Pro Tip: Use a stopwatch and a measuring wheel during the observation phase. Data based on intuition is rarely as effective as empirical evidence.
• Pro Tip: Focus on the "Transportation" and "Delay" categories. These are almost always non-value-added and provide the lowest-hanging fruit for cost reduction.
• Pitfall (The "Ideal" Trap): Do not chart the process as it is supposed to happen; chart it as it actually happens, including the mistakes and workarounds.
• Pitfall (Too Much Detail): Avoid over-complicating. If a sub-process is too complex, create a separate "drill-down" chart rather than cluttering the master flow.

FAQ

Q: How does a Flow Process Chart differ from a standard Process Map? A: A Flow Process Chart is a tabular, analytical tool that emphasizes metrics like time and distance for each step, whereas a standard Process Map is primarily a visual representation of the logical flow and decision branches.

Q: Should I include every micro-step in the chart? A: Only include steps that are relevant to the objective. If the goal is to reduce cycle time, prioritize recording transportation and delay times over minor administrative tasks.

Q: What is the most important symbol to focus on when trying to save money? A: Focus on "Transportation" and "Delay." These represent wasted time and motion that add zero value to the product or service, directly impacting your bottom-line labor and overhead costs.