Lean Tools, Training, and Systems

Block Diagram creator

Block diagram creator for a functional block diagram or process block diagram

What is a Block Diagram?

Use a your Block Diagram template (BlockDiagram.xlsx)

to create a simple, visual, high-level sketch of a process showing only the Major Steps, their sequence, number of operators, inventory levels, cycle time, and perhaps just a little more optional information.

Sample block diagram example

Why use a Block Diagram creator?

Why not just draw by hand?

For the same reasons that you use any software

To have a standardized process
to remind your team of all the factors you are supposed to consider in every block diagram
So that your end product is legible
and understandable, even to people who didn't participate in drawing it
To have help and training
to remind your team of how to do this (infrequent) process improvement activity

How to use your

Block Diagram template

Also known as a block diagram template, or block diagram software

Find and open your template

Find and open your Block Diagram template

(BlockDiagram.xlsx)

in the same way that you find and open your other 150+ Systems2win templates.

Save your working document

following the usual document storage and naming conventions established by your leaders

Open a Blank Sheet

When you're ready to start doing your own real work...

click the button to 'Open a Blank Sheet'

Excel Ribbon > Systems2win tab > Open a Blank Sheet

This blank sheet is where you will do your real work

(not on the Sample sheet — which gives you sample data that is extremely helpful for learning how to use your new tool, but is the wrong place to do your real work)

Rename your new sheet.

Or... Insert Sheet

As an alternative to opening a stand-alone document (as instructed above), you also have the option to Insert Sheet into any other Excel workbook.

If English is not your preferred language

Switch to your language, just like every Systems2win Excel template.

Now your team is ready to start using your

Block Diagram template

to create a Functional Block Diagram

Observe the Process

Using one of your Time Study templates, physically go to the place where the work is done.

Do not use existing process documentation or past memories.
Go to the gemba.

Sketch the Major Steps of the Process

Use one block for each sub-process.

For more sub-processes, simply copy & paste columns.

Enter a brief description in each Process Box.

A block diagram should not be overly detailed.

There shouldn't be decision branches or layout measurements.
Just one box for each Major Step.

Familiar Microsoft Excel

Use everything you know about familiar Word and Excel

Enter some minimal information for each Step

Who does it? Where?

How much inventory? Where?

Maybe just a little more optional information that you believe to be very relevant.

Optionally use symbols to make your block diagram more visual.

Use everything you know about how to use Excel as a drawing tool.

Observe the Cycle Time

Using your Cycle Time Observations template, (ObservCycles.xlsx)

Choose one point in the process (usually the point where the finished product emerges), and use a stop watch to record how long it takes for another finished product or batch to emerge.

No matter what "unusual" things happen during the cycle, just record how long it takes.

Then enter the lowest repeatable time in the Cycle Time field on your Process Block Diagram template.

Lowest repeatable time is usually the second-to-the-fastest observed cycle.

If there is a sub-process that has a different Cycle Time, then record both the Default Cycle Time for the primary process, and the unique Cycle Time for the sub-process.

Do any other Process Analysis

The Block Diagram is almost never used as a stand-alone tool.

It is almost always used in conjunction with other Process Analysis Tools.

Improve the Process

The ultimate objective is to actually improve the process.

Like every other lean tool and method...

the primary benefit is to stimulate people to ask Hansei questions for Lean Thinking.

Other tools often used

with your Block Diagram template

Tool Selection Matrix

Perhaps use your Tool Selection Matrix (1ToolSelection.xlsx) to identify a few possible choices for how to approach the various challenges that you might encounter.

Kata Coaching

The Block Diagram is probably most popularized by the Toyota Kata community, to conduct PDCA scientific experiments to understand and improve a process.

Process Analysis

Rather than trying to cram too many details into your block diagram, use your Process Analysis template to highlight and measure ANY metrics that are important to the success of YOUR process.