In my previous articles, I introduced two essential Lean Six Sigma tools:

1. The Project Charter – The foundation of a Lean Six Sigma project, defining the problem, goals, and scope.

2. SIPOC – A high-level process map that identifies Suppliers, Inputs, Process steps, Outputs, and Customers.

Now that we have a clear understanding of the overall process, it’s time to dig deeper and analyze how work actually flows—and that’s where Process Mapping comes in.

Where Does Process Mapping Fit in DMAIC?

Process Mapping is a tool used in both the Define and Measure phases of DMAIC (Define, Measure, Analyze, Improve, Control).

• In the Define phase – It helps provide a clearer picture of the process before making changes.

• In the Measure phase – It helps identify where delays, bottlenecks, and inefficiencies occur.

By creating a detailed Process Map, I can visualize how work moves from start to finish, spot inefficiencies, and set a foundation for improvement.

What is Process Mapping?

Process Mapping is a way to graphically represent a process, showing the sequence of steps, decisions, and interactions. It helps answer key questions:

• What happens at each stage of the process?

• Where are the delays or bottlenecks?

• Which steps add value, and which are wasteful?

Types of Process Maps

There are different types of process maps depending on the level of detail needed:

1. Basic Flowchart – A simple step-by-step process diagram.

2. Swimlane Diagram – Shows interactions between different teams or departments.

3. Value Stream Map (VSM) – A Lean-specific map that highlights value-added vs. non-value-added activities.

For this article, I’ll focus on the Basic Flowchart—the easiest and most widely used form of Process Mapping.

How to Create a Process Map Step by Step

Let’s say I’m working on reducing order processing time, as defined in my Project Charter. My SIPOC identified the major steps, but now I need a more detailed view.

Step 1: Define the Start and End Points

Every process map should have a clear start and end.

✅ Example:

• Start: Customer places an order.

• End: Customer receives their order.

Step 2: List the Key Steps in Sequence

Write down the main steps of the process in order.

✅ Example:

1. Receive customer order

2. Check inventory availability

3. Process payment

4. Pick items from warehouse

5. Pack and label order

6. Ship order

7. Send tracking number to customer

Step 3: Add Decision Points (If Needed)

Some processes involve decision-making, such as approvals or checks. These are represented with diamond-shaped decision nodes.

✅ Example:

• If inventory is available, proceed to payment.

• If inventory is not available, notify customer and suggest alternatives.

Step 4: Draw the Process Map

Using basic symbols:

• Ovals = Start & End Points

• Rectangles = Process Steps

• Diamonds = Decision Points

• Arrows = Process Flow

Here’s a simplified process map for order fulfillment:

Step 5: Review and Validate

Before using the Process Map to make improvements, I review it with team members to ensure accuracy.

✅ Questions to ask:

• Are all process steps included?

• Are there unnecessary delays or approvals?

• Where do errors or bottlenecks occur?

How Process Mapping Helps Identify Waste

A Process Map doesn’t just show steps—it reveals inefficiencies. Here’s how:

✅ Identifying bottlenecks – Are there unnecessary approvals or slow handoffs?

✅ Spotting rework loops – Do mistakes cause steps to be repeated?

✅ Highlighting waste – Are there delays, unnecessary steps, or waiting periods?

For example, if I notice that checking inventory takes too long, I can investigate why—perhaps the system updates are slow, or staff are manually verifying stock.

How Process Mapping Links to the Next Steps in DMAIC

Now that I’ve mapped the process, the next step is to measure performance. This includes:

• Cycle times (how long each step takes)

• Defect rates (where errors occur)

• Work-in-progress (where tasks pile up)

These insights will help prepare for the Analyze phase, where I’ll use tools like Fishbone Diagrams and 5 Whys to find root causes of inefficiencies.

Next Up: Measuring and Analyzing Process Performance

Now that I’ve covered Process Mapping, the next step is to analyze where the biggest inefficiencies come from. In the next article, I’ll introduce tools like Cycle Time Analysis and Value-Added vs. Non-Value-Added Analysis to measure process performance.

Stay tuned!