“To Be” Process Map

Johnson Controls, Inc. © January 2006 1 W3"ToBe"ProcessMap.ppt

 “To Be” Process Map
In Improve Phase, the team creates the process map that
shows how the new, improved process will work.

The Six Sigma team must ….

1. Not create additional procedures that make work more
difficult for the people in the process, especially without
an associated gain.
2. Install solutions and controls that make the new process
easy for the people who work in the process.

Johnson Controls, Inc. © January 2006 2 W3"ToBe"ProcessMap.ppt

 Example of “As Is” Cross Functional Map
Customer
Walkthrough
No Walk Walk
Scheduled
through through
Re- Complete
Field Walk scheduled
Field Work
Through
Engineer Complete
Cancelled

Yes

Project Customer
Survey Walkthrough
Manager Form Sent is Walkthrough
rescheduled Completed
70% of the only 40% of
Final As-built time* the time*
Design Drawings
Engineer Complete

Walk
Service Walkthrough through Walk
through
Technician As-built Scheduled Re-
Complete
Drawings are scheduled
accurate 50%
of the time*
Service
Supervisor

Warranty
Service Information Warranty
is inaccurate Information
Admin 50% of the Entered
time* into System
* Survey Opinion Data to be validated in Analyze Phase
Johnson Controls, Inc. © January 2006 3 W3"ToBe"ProcessMap.ppt
 Example of “To Be” Cross Functional Map
Customer
Walkthrough Walk
Scheduled through
Complete
Field Field Work Final As-built
Engineer Complete Drawings
Complete

Customer
Project Survey
Manager Form Sent

Final As-built
Design Drawings
Engineer Complete

Service Walk
Walkthrough through
Technician Complete
Scheduled

Service
Supervisor

Service Warranty
Information
Admin Entered
into System

Johnson Controls, Inc. © January 2006 4 W3"ToBe"ProcessMap.ppt

 Initial Expendable Packaging Process

DCX Issues PO

Example of
with Clause Build product
electronically
through 850

No PO's found in

“As Is”
850 mailbox
Returnable
Containers
Available?
Locate PO's NVA

Linear Map
No

Print PO and key Expendables

into QAD used

Create ASN
Enter PO
Is Clause 092 without
NVA on PO?
No
setting up
XP part

Yes Is price in
QAD? Yes
Enter PO, Yes
set 092
flag to Yes No

No price on Clause 092

ASN price on ASN

Run "Impromptu"
Edit report weekly
for 092 setup Shipping notifies
Scheduler of
expendable No
Has XP part
packaging been setup

Look up 092
clause amount in
BASIS & Eliminate Send ASN & ship Yes
all 092 parts with parts Shipping notifies
no price. Scheduler of
expendable
packaging
No reimbursement
Look up sales for XP
orders & enter Send ASN & ship
correct 092 price parts

MFG/PRO
Receive
reimbursement for
XP

Johnson Controls, Inc. © January 2006 5 W3"ToBe"ProcessMap.ppt

 New Expendable Packaging Process
DCX Issues PO

Example of
with Clause Build product
electronically
through 850
Improvement (X4): Automated

“To Be”
PO's automatically process Should
moved into BASIS expendable
PO System packaging be
used?

Linear Map
Yes

Expendables
used

Print PO and key

into QAD
Create ASN

Improvement (X2): XP Parts set up

with price by Materials when
production part is set up. Clause 092
price on ASN

Shipping notifies
Scheduler of No
Enter PO, expendable
set 092 packaging
flag to Yes

Send info to Linc

Improvement: (X5)
Contact LINC when
Improvement (X3): AR to run Obtain incidence shipping XP
0$ Ship Report and link price number from Linc
in QAD

Forward incidence
number to A/R

Send ASN & ship

parts

MFG/PRO Receive
reimbursement for
Johnson Controls, Inc. © January 2006 6 XP W3"ToBe"ProcessMap.ppt
 Exercise 3.1 - Analyze Process Maps

1. Refer to your workbook.

2. Describe the differences you see

between the “As Is” and “To Be” process
maps shown in this module.

Johnson Controls, Inc. © January 2006 7 W3"ToBe"ProcessMap.ppt