SIPOC and Training

Word came back from Curds and Whey head office of the approval of the aseptic project. The plant's favourite engineer had been assigned as the project manager and a new graduate was going to be supporting him to gain experience and knowledge.


As Eva wanted the engineers as focused as much as possible on the project, she asked us at Edge for guidance on how to get the engineer up to speed as fast as possible on plant operations. We discussed how a large element of training is purely hands-on application of the book knowledge and direct involvement in the process. Since anything in school will be more of a general nature and each operation has its slight differences be it age, or youth, of the equipment itself, the best start is to do a process map of the operation.



There are different types of process maps but in this case, the first on to do is the most basic, called a SIPOC (Supplier-Input-Process-Output-Customer).



Start with the middle, "Process" and describe it in 5-9 steps. More than 9 steps and it is too detailed for this stage and less than 5 and it is not detailed enough. Once the high level map is done, then look to the inputs to the process and the outputs. Some external inputs occur in the first step (ie raw milk, trained employees, water) and some occur at later steps (H2O2). Identifying when a new energy source, ingredient or packaging is added is key to greater understanding of the whole. When doing the outputs, using the same idea, it is always important to remember the waste streams as well as intermediate and final products.



Now you have an idea of what is going in, what is coming out and what happens inbetween. Next on the list is S and C ->Suppliers and Customers.



Look at individual inputs and determine who the key supplier is and in some cases, the secondary suppliers. Do the same with the outputs and customers. Don't forget that for both the supplier and customer, it may actually be another area of the plant. Also you may want to capture the data trail associated with the process.



Eva chose what was probably the best way to introduce the process to the trainee engineer -> Eva made the engineer create the SIPOC diagram herself, getting her to go to people and ask questions, thus building relationships as well as knowledge and experience of the process.