Lean Six Sigma Manufacturing Process Tool
Map processes, identify waste, and optimize manufacturing workflows with our free Lean Six Sigma tool.
1
Process Setup
Define process basics
2
Map Steps
Add process activities
3
Analysis
Visual process flow
4
Results
Summary & export
Step 1: Process Setup
How Lean Six Sigma Process Mapping Works
What is Lean Six Sigma?
Lean Six Sigma combines Lean Manufacturing principles (waste elimination) with Six Sigma methodology (quality improvement) to optimize manufacturing processes. Our tool helps you map current processes, identify waste, and design improved future states.
The 8 Types of Waste (TIMWOODS):
- Transport - Unnecessary movement of materials
- Inventory - Excess stock or work-in-progress
- Motion - Unnecessary movement of people
- Waiting - Idle time in processes
- Overproduction - Making more than needed
- Overprocessing - Doing more work than required
- Defects - Errors requiring rework
- Skills - Underutilized human potential
Benefits for Manufacturing
- Reduce process cycle times by 25-50%
- Eliminate non-value-added activities
- Improve product quality and consistency
- Reduce manufacturing costs and waste
- Increase overall equipment effectiveness (OEE)
- Enhance customer satisfaction
- Create standardized work procedures
- Enable continuous improvement culture
4-Step Process Improvement
1
Process Setup
Define the process scope, objectives, and key stakeholders
2
Map Current State
Document all process steps with times and waste identification
3
Analyze & Visualize
Review process flow and identify improvement opportunities
4
Export Results
Generate reports and action plans for implementation