Process Mapping
Process mapping is a visual way to document how work, material, and information move through a process from start to finish.
The goal is to make the actual process visible—not just how it is supposed to work. A good process map can reveal delays, unnecessary handoffs, duplicated work, bottlenecks, rework, and steps that add little or no value.
What Is Process Mapping?
Process mapping is a visual way to document how work, material, and information move through a process from start to finish.
The goal is to make the actual process visible—not just how it is supposed to work. A good process map can reveal delays, unnecessary handoffs, duplicated work, bottlenecks, rework, and steps that add little or no value.
What Process Mapping Looks At
Process Steps — What actually happens from the beginning of the process to the end?
Material Flow — How far does material travel, where does it wait, and how many times is it handled?
Information Flow — How do drawings, work orders, approvals, schedules, and other information move through the process?
Handoffs — Where does responsibility move from one person, department, or machine to another?
Delays & Queues — Where does work sit waiting for people, material, equipment, information, or approval?
Rework & Loops — Where does work repeatedly move backward through the process because something was missed or completed incorrectly?
Why Process Mapping Matters
A process can look efficient when each individual step is viewed separately while the overall workflow is creating unnecessary time and cost.
Process mapping can help identify:
- Bottlenecks
- Excessive material movement
- Unnecessary handoffs
- Waiting time
- Rework
- Duplicate steps
- Poor communication between departments
- Opportunities for automation or layout improvement
When Process Mapping Makes Sense
Process mapping is especially useful when:
- Lead times are longer than expected
- Work regularly gets stuck between departments
- Employees have different understandings of the process
- Production problems keep recurring
- Material travels farther than it should
- A process is being redesigned or automated
- A new layout or piece of equipment is being considered
BrewerMade’s Approach
BrewerMade focuses on documenting what actually happens on the manufacturing floor, not simply what the procedure says should happen.
The goal is to identify practical opportunities to simplify the process, reduce wasted movement and waiting, improve flow, and make better use of people, equipment, and floor space.