Process Flow Charting 240

This class covers the purpose and methods of flow charting, including spaghetti diagrams, process maps, and value stream maps.

Class Details

Class Name:
Process Flow Charting 240
This class covers the purpose and methods of flow charting, including spaghetti diagrams, process maps, and value stream maps.
Number of Lessons:
Additional Language:
Related 2.0 Class:
Process Flow Charting 241

Class Outline

  • Objectives
  • Process Flow Charts
  • Process Values
  • Metrics
  • Tools for Flow Charting
  • Present-State Process Flow Charting
  • Future-State Process Flow Charting
  • Product Families
  • Types of Process Flow Charts
  • Present-State Spaghetti Diagram
  • Future-State Spaghetti Diagram
  • Sample Present-State Spaghetti Diagram
  • Sample Future-State Spaghetti Diagram
  • Present-State Process Map
  • Future-State Process Map
  • Value Stream Mapping
  • Value Stream Map Layout
  • Present- and Future-State Value Stream Maps
  • Pros and Cons of Flow Charting
  • Summary


  • Describe the purpose of flow charting.
  • Describe how flow charting helps manufacturers eliminate waste.
  • Describe the relationship between flow charts and metrics.
  • Describe the key characteristic of flow-charting tools.
  • Describe the purpose of a present-state flow chart.
  • Describe the purpose of a future-state flow chart.
  • Organize typical manufacturing products into families.
  • Distinguish among the main types of process flow charts.
  • Describe the purpose of a present-state spaghetti diagram.
  • Describe the purpose of a future-state spaghetti diagram.
  • Identify the actions needed to create a present-state spaghetti diagram.
  • Identify actions that transform a present-state spaghetti diagram into a future-state spaghetti diagram.
  • Match common process-mapping symbols with their descriptions.
  • Describe the advantages of using symbols in process maps.
  • Distinguish between categories of symbols used in value stream mapping.
  • Identify the direction of flow for each section of a value stream map.
  • Describe the main purpose of a future-state value stream map.
  • Describe drawbacks of flow charting.


  • MSSC Manufacturing Processes and Production


Vocabulary Term Definition
changeover time The time it takes to convert a machine from one process to another. Changeover may require switching fixtures, tools, programming, and other aspects of the manufacturing process.
cycle time The actual time it takes to perform a task and forward it to the next step. One of the major goals of lean is to match cycle time to the customer's requirements.
future state The improved condition for a process. A future-state flow chart maps out the manufacturing process as it should be, with all possible flaws and errors eliminated.
information symbol A type of value stream mapping symbol that indicates the form, flow, and direction of communication and data. A jagged arrow, which represents electronic information, is an example of an information symbol.
material symbol A type of value stream mapping symbol that indicates the origin, location, and movement of raw materials and parts within the system. A triangle, which represents inventory, is an example of a material symbol.
metric A measured variable that is tracked and can be used to detect errors or variation and make improvements.
muda A Japanese term meaning waste.
non-value added Activities that do not contribute to the product or the process and should therefore be eliminated. Non-value added steps are waste.
non-value added but essential Production activities ensuring that the value-added steps have been properly completed. For example, inspection does not contribute to the product, but it is necessary unless the process can be improved to the point where inspection can be eliminated.
present state The current condition of a process. A present-state flow chart captures all of the details of a manufacturing process just as it is at the moment the chart is produced, including any flaws or errors.
process flow chart A visual representation of the steps required to manufacture a product.
process map A flow charting method that uses general symbols and arrows to show the flow of the manufacturing process.
process symbol A type of value stream mapping symbol that indicates the actions that take place or the locations where processes occur. A U-shaped symbol, which represents a cell, is an example of a process symbol.
product family Products that are grouped together based on the fact that they use the same machines or processes.
spaghetti diagram A flow charting method that uses a continuous line to trace the path of a part through all phases of manufacturing. Spaghetti diagrams expose inefficient layouts and large distances traveled between steps.
value added Any step in the production process that improves the product for the customer.
value stream map A sophisticated flow charting method that uses symbols, metrics, and arrows to help visualize processes and track performance. This method helps determine which steps add value and which do not.