Key Points

• SIPOC diagrams are a useful way of providing a transparent overview of a process.
• They can help eliminate waste and increase process stability.
• They aren’t comprehensive problem-solving tools, but can aid in solving issues.

Why should you start a SIPOC diagram at the start of your Lean Six Sigma Projects? Many facets go into planning and executing a project. The last few years have seen the rise of software-centric methodologies like Agile and DevOps, which have become prominent outside of the tech industry. However, SIPOC diagrams remain a useful and crucial tool for anyone planning a project. Today, we will explore a bit of the why behind this tool.

What Are SIPOC Diagrams?

Before diving into the real meat of today’s article, let’s take a moment to define these tools. SIPOC diagrams are a high-level process mapping tool used during the Measure phase of DMAIC. Chances are, if you’re in an organization that utilizes Lean Six Sigma, you’ve used SIPOC diagrams at least once.

They aren’t what we would call a specialized tool, at least in the context of the Lean Six Sigma methodology. Unlike more specialized visualization or mapping tools, they are a high-level overview of the flow and structure of a given process.

SIPOC diagrams can be simple in concept to create, which is a strength and weakness as we’ll explore further. However, the simple fact remains that these useful maps provide a means to keep everyone on the same page when it comes time to plan out and execute processes. With that in mind, let’s shine a little more light on this useful tool and leave no stone unturned in the process.

Defining SIPOC Diagrams

So, we’ve explained a bit behind SIPOC diagrams, but haven’t fully loosed all the details. These are simple diagrams as previously stated. SIPOC, and conversely COPIS, is an acronym, that identifies all the relevant parties and components of a process. They are high-level, meaning there isn’t going to be much in the way of detail when it comes time to develop a process.

You’re identifying the Suppliers, Inputs, Processes, Outputs, and Customers throughout. COPIS is a complementary diagram to SIPOC and is a reversed order, however, creating these diagrams is identical in workflow. We’ll go over every step you’ll want to include in your diagrams if you’re just getting started leading a project.

Suppliers

Suppliers can be seen as the stakeholders in a given project. However, rather than identifying every single supplier in a given project, you’re identifying those with an immediate impact. This can come in the form of raw materials for manufacturing, funding, or anything else that is going to sway your project’s creation.

Keep this section brief, as you want to devote time and energy to suppliers who will directly affect your project. While you can certainly identify other stakeholders and leaders later in the planning process, that isn’t the point of SIPOC diagrams.

Inputs

You’ve identified the suppliers, now it’s time to sit down and mark out your inputs. Inputs come in a few different forms. If you’re in the business of manufacturing, this can be raw materials or goods that you use during production. However, this isn’t applicable if you’re in the tech industry or a customer-driven field.

At any rate, whether it is data or materials, you’ll want to identify exactly what is needed for your process’s inputs at this stage. After preliminary trials of identifying these items, meet with your leadership and stakeholders to ensure these align with your current project’s scope.

Process

It seems a bit redundant naming process as the next step in your SIPOC diagram, but there is a purpose to it. This is for the actions and tasks needed to complete your project. As a general example, this might be something like producing a product.

This can include anything needed during the production cycle, like applying paint to a car and assembling its interior. The final result directly ties into the next component, as all named parts of the diagram do. As with the previous pieces of the diagram, you want to take a high-level look at what needs to be done to complete a product.

Outputs

Outputs are whatever is getting delivered. This could be like a finished car being taken to a dealership and being purchased, just as a general example. Typically, in most LSS projects this is going to be the final result of your production line, whether it is products, services, or actions that respond to your customer’s needs.

Customers

The final consideration in any SIPOC diagram is customers. This section of your diagram should have the needs and demands of anyone who is using your outputs. Further, you should take a hard look at what impacts customers have on your processes.

This directly corresponds with the Lean Six Sigma methodology when considering value. As with any data-driven approach, you’ll want to pay close attention to things like the voice of the customer when drafting out the items contained in this section.

Benefits of Using SIPOC Diagrams

As you might imagine, there are quite a few benefits to using something high-level before starting a project. We’re going to take a closer look at some of the net benefits of implementing these diagrams in your LSS projects, but it isn’t all a bed of roses either as you’ll discover.

Built-In Problem Solving

Problems arise in any project, that’s just the way it goes. However, when you’re constructing a SIPOC diagram you’re giving yourself the means to rectify issues as they arise. When you’ve got all the bare elements of a project laid out, it means you readily can single out issues where they come up.

It isn’t going to serve as a magic wand to rectify issues, but it can help you single out chokepoints where they might occur.

It’s a High-Level Overview

Too often, we can’t see the forest for the trees in a project. We get bogged down in the minutia without considering the grander scale of a project. When you’re in a leadership position, further down a production line, this can bog down team morale.

However, this is where these diagrams shine. You’re getting everybody on board, and you’re taking a look at the bigger picture. This ties directly into my next point since any project is a team effort.

It Facilitates Transparency

One of the greatest benefits of using a SIPOC diagram in your project planning is that it keeps everyone on the same page through open transparency. No one involved in the creation of a diagram is being left out by lack of knowledge or experience.

Since it is a high-level overview, you see what needs to be done by everyone involved to get things up and running.

You’re Identifying Your Suppliers and Customers

This might seem like a given, but one of the core advantages of using these diagrams is seeing exactly what is going into any project. You might be familiar with the inputs and outputs of a process, but it gets harder to identify those directly impacted by your project.

As such, having your suppliers and customers identified from the very start is a net benefit for anyone looking to deeply understand their processes.

Disadvantages of SIPOC Diagrams

No tool is perfect, they each have a time and use. However, that doesn’t mean you should avoid the use of these diagrams. That said, it is worth taking some time to illuminate issues present in creating these diagrams.

They May Not Fully Solve Process Issues

We’ve discussed how these diagrams can benefit problem-solving, but they don’t provide a foolproof solution. While it might be useful for providing transparency and identifying potential issues, it isn’t going to be the bedrock for solving all potential problems.

You’ll want other strategies in place, as these diagrams aren’t monolithic entities. Having problem-solving apparatuses or tools in place during your production workflow is going to increase your odds of success.

You’ll Need Other Tools

Believe it or not, a high-level view of your process isn’t going to paint a complete picture. While this is great for keeping everyone on the same page, you’re likely going to need other tools to complement the SIPOC diagram.

Think of it like building a house, you’ve got a great floorplan, but this isn’t going to put up the walls and foundation. You’ll need specific tools for every step involved. That said, it serves more as a framework to approach the development of new projects and improve others, but it won’t do the work needed to accomplish those goals.

It’s a Straightforward Means of Mapping Processes

I keep harping on about potential problems and issues that arise, but it is a real possibility. As such, you’ll want other tools and plans in place throughout to account for the likes of variation, potential issues, and far more.

While having a straightforward means of keeping everyone on a project on the same page is a net benefit, it can obfuscate some of the details that need to get ironed out later.

How It Relates to Lean Six Sigma

We’ve talked at length about the benefits of the SIPOC diagram, but where does it tie into Lean Six Sigma? You’re likely familiar with DMAIC, which serves as a crucial methodology for the development and improvement of processes. These diagrams are typically used in the very first phase of any DMAIC project, Define.

Since they provide a visual means of seeing your suppliers, inputs, and more, they are instrumental in accomplishing one of the core goals of developing or improving any processes. You’re looking to remove or reduce variation as much as possible.

While something like an Ishikawa Diagram can help you drill down to the causes of a potential issue, you might get the nudge you need from implementing a SIPOC diagram beforehand. It can make processes more stable and predictable, which any LSS practitioner knows is vital for production lines.

Other Useful Tools and Concepts

As we draw to a close with today’s topic, you might be on the hunt for some extra materials to bolster your project planning. Some organizations might do well to implement and design COPIS diagrams alongside SIPOC diagrams. These can be a great way of listening to your customer’s needs since they put the customer first by design.

Additionally, you might look into the rapid organizational changes you can enact through the likes of CAP. Change Acceleration Process finds its roots at General Electric, but applies to any organization, regardless of your industry.

Conclusion

So, are SIPOC diagrams integral to Lean Six Sigma? I would certainly say so. These useful tools are only going to help your organization when you get right down to it. They might not be a solution for every potential issue that arises, but they will get your team on the right track.

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