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Creating and Using a Shingo-Style Process Map: A quicker path for finding waste and eliminating process problems, by Peter C Gaa
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Process maps have been a critical part of improvement efforts for decades. Shingo-style process maps are one of the least-used but most valuable improvement tools. They have many advantages over other process mapping approaches: • They can be used on any type of process in any work setting: offices, factories, retail shops, hospitals, schools, labs, etc. • They require little or no data. You just need to know the flow from input to output. • They are effective at showing all the moving parts in a process—information, materials, machines, and people—plus where and how variation gets created. • They allow you to more quickly pick out the three main targets for improvement—waste (especially hidden waste), inconsistencies, and unfairness. And they help you uncover the root causes of these problems quickly. • They can be easily linked to specific changes that will eliminate the identified problems, including all the classic Toyota Production System solutions (work standardization, 1-piece flow, mistake proofing, etc.). • Because of their unique format, a completed Shingo-style process map of an improved process can easily become part of a standard operating procedure format. This book provides the how-to around Shingo-style process maps. You’ll learn how to create the map, what kinds of data or estimates to include, how to clearly mark problem areas, which calculations can help you understand process performance, and how to interpret the map to make quick improvements in your own processes.
- Sales Rank: #1630498 in Books
- Published on: 2015-09-05
- Original language: English
- Dimensions: 11.00" h x .34" w x 8.50" l,
- Binding: Paperback
- 142 pages
About the Author
Peter Gaa has helped global firms across many industries and government agencies improve their processes in the office and factory. He has led hundreds of kaizens using Shingo-style process mapping. He is a Master Black Belt in Lean Six Sigma (LSS) and a Lean Master. He has 34 years of experience conducting kaizens in pharmaceutical, chemical, plastics, banking, consumer products, software development, electronics, and automotive industries. He also improved military-type processes within the US Army and Navy in Kuwait, Afghanistan, and the United States of America. In past positions, Pete has led research, development, manufacturing, and quality departments in companies within the plastics, chemicals, and electronic industries in the United States of America and Japan. He has earned 18 US patents on new products and processes.
Most helpful customer reviews
3 of 3 people found the following review helpful.
The World of Continuous Process Improvement is Shaken Up
By William S. Gripman
This is a real how to book. It dramatically transforms value stream mapping for the better. Pete's method should be the standard used by all continuous process improvement experts. The book itself is a clear step by step approach that can make anyone an expert in short order.
Full Disclosure: I worked with Pete as he developed and refined these methods, so I completely understand just how earthshaking this book is.
2 of 2 people found the following review helpful.
Process Maps and Swimlanes for year with great success (or so I thought)
By timewilltell
When Pete showed me this mapping method I was very skeptical. After all I had been mapping using Value Steam Maps, Process Maps and Swimlanes for year with great success (or so I thought). Then a need arose at a client to map a very complicated administrative process with many, many options for flow, huge rework and very long cycle times. Using what I had done before I may have been able to get there, but by using the method Pete describes, we found an amazing number of opportunities for improvement immediately as we mapped the process using the Shingo method. The fact that you get so much information and detail from this method makes it a remarkably rich method for understanding and improving any process. Now that I have used this method on hundreds of processes, it is my go to method to achieve dramatic improvement. Once the map is complete it is easy to understand by anyone and at the same time can handle the most complicated processes and help you pinpoint the specific areas to start working on improvement.
2 of 2 people found the following review helpful.
Structured, Simple method for removing waste and improving ANY process.
By Wade Harper
As an engineer I have been designing and analyzing processes for almost 30 years. I had the pleasure of working with Dr. Gaa and learning his methods and I have not found anything else that works as well on ALL processes (manufacturing, service, administration). I have found most service and administrative processes are not documented and have very little, if any data. The Shingo-Style Process Map will allow you to gather the intellectual capital from the subject matter experts and use the data gathered from them, and walking the Gemba, to make significant improvements to any process.
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