Continuous Improvement Toolkit
for Business and Life!
Lean Tools Guide
Yellow Belt Guide
Green Belt Guide
Black Belt Guide
DMAIC Process Guide
Basic Quality Tools
This is an example of a process map that illustrates the process for equipment installation. Notice the two rework loops to indicate the activities that are repeated.
This is an example of a process map for doing the laundry in the old fashioned way (the washer and dryer are separated).
This is a process map for making orange juice. This process may be part of a larger process (e.g. preparing breakfast). Also, each step can be decomposed further (e.g. you may describe how to peel and slice the oranges).
An example of a process map for repairing a defective unit after received by a customer. Notice that there is only one process step which has been mapped to a second level.
An example of a process map that illustrates the process for making two-piece aluminum beverage cans. The process begins with preparing the aluminum coil and ends with palletizing the cans.
The purpose of this example is to help identify all possible sources of variation that could have an influence on the performance of the process (expense payment for employees). Note that there are only two factors that could be adjusted.
This process map shows the steps required to make coffee drink. Note that there are only eight controllable factors that could be adjusted to influence the quality and taste of the coffee.
This is called a time-function process map, which is a process map with the time added on one axis and the function on the other axis. It is useful to identify and reduce the waiting times.
More information can be displayed in process maps using this tabular format, including the time it takes to perform each activity, the responsible person for each activity, input variables, KPI’s, etc.
A cross-functional flowchart (or a swimlane flowchart) illustrates the sequence of activities required to accomplish a cross-functional process.
This is an example of a flowchart that illustrates the process for making a cup of tea. Cycle time here is the time needed to prepare the cup of tea.
This is an example of a flowchart that illustrates the process for preparing reports for decision makers. Notice how the performance indicators that need to be tracked were added above three of the steps.
This is an example of a flowchart that was created for a changeover operation (size conversion) for a production line.
This example illustrates a cross-functional flowchart for acquiring new equipment by a company’s business unit.
This opportunity flowchart illustrates the use of an office copy machine. Regularly cleaning the glass and checking the availability of papers are examples of ideas to improve this process.
This flowchart shows the process used to process an order from the time the sales takes the order until the product is shipped from the warehouse.
This is an example of a flowchart that was created by an IT department to help in designing and documenting computer programs. Notice the use of ‘technical’ shapes other than the basic ones.
This flow diagrams illustrates the movement of a document after received until it is sent to the archive.
An example of a process chart summary, which is useful to estimate key performance metrics such as the total time to perform a process and the distance travelled.
An example that uses the process chart for processing an invoice after received by the supplier. The process begins after receiving the invoice and ends with paying the supplier.
An example that uses the process sequence chart for processing an invoice after received by the supplier. The process begins after receiving the invoice and ends with paying the supplier.
A process sequence chart that was prepared for an egg tray production line. This is an example of a material-type process sequence chart.
An example of a process sequence chart for inspecting samples in a production line, which is a man-type process sequence chart.
An example that uses the paired comparison analysis to decide how to spend a summer holidays. Here, the highest rank is the third option, that is, spending time with family.
This is an example that uses the paired comparison analysis to identify and rank the top motivators for a team.
An example that uses Force Field Analysis to decide whether to employ an internal or an external consultant.
An example that uses Force Field Analysis to decide whether to implement a content management system or not.
An example of a mind map that was created to help remembering the continuous improvement tools and techniques.
An example of a mind map that was created to organize perspectives and objectives using the balanced scorecard strategic management approach.
An example of a mind map that was created to help remembering personal development tools and techniques.