Input-Process-Output (I-P-O)
Input-process-output (I-P-O) is a structured method for recording and illustrating all inputs, outputs, and process steps required to transform inputs into outputs. This ensures that your project aligns with the Lean Six Sigma scope.
This model is often called an I-P-O model or I-P-O diagram, highlighting the method's intended visual depiction. Due to its remarkable adaptability, this approach is employed in various industries and sectors adopting the Lean Six Sigma methodology, often with particular modifications and adaptations.
Utilizing the I-P-O Model
Generally, in the "define" stage of a Six Sigma DMAIC project, we utilize I-P-O and adhere to a particular method for creating the model.
The first step in creating the I-P-O Model is to
Determine the process steps to be included within the model's scope. Aim to keep the scope manageable by defining fewer than 10 process steps.
Utilize the SMART framework to ensure your scope of work is attainable. Avoid being overly ambitious by incorporating too many process steps into your I-P-O model. If you identify 10 or more process steps, it is advisable to pause and reassess your approach.
Once you determine the process step, the following steps are:
List all possible outputs, including any potential error conditions.
To succeed in DMAIC and I-P-O, it is essential to collaborate as part of a team. Even seemingly straightforward processes involve multiple inputs and outputs. Moreover, team members often possess in-depth knowledge of specific process inputs and outputs. It is prudent to leverage this collective expertise effectively.
Identify all inputs associated with the process and outline your steps using precise and descriptive language.
Ensure that all inputs and outputs are thoroughly considered. The next step is to organize your data into a visual model. It is crucial to be meticulous, involve the entire team, and eliminate bias—avoid listing inputs and outputs based on ideal assumptions. Additionally, all potential output error states should be considered and documented.
Develop a visual representation.
It is now necessary to validate your visual model by:
Verify that the inputs are converted into outputs through the process steps, as illustrated in the model.
The team developing the I-P-O model often benefits from conducting a Gemba walk. Additionally, visiting the actual workplace and observing the process in action can reveal some less apparent inputs and outputs, thereby enhancing the continuous improvement of the current process steps.
What are the advantages of utilizing the I-P-O model?
Easy to Explain, aided by the visual model
Simple to implement
The main limitation of the I-P-O model is that it omits Suppliers and Customers, which are included in the SIPOC model. This model is designed for internal business process applications.
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