SIPOC and process mapping
A SIPOC (Suppliers, Inputs, Process, Outputs, Customers) diagram defines the scope of a process at a high level before detailed mapping begins. It is one of the first tools used in the Define phase and is commonly reviewed at the Define tollgate. A process map then shows what actually happens step by step — the as-is state the team will analyze and improve.
SIPOC structure
| Column | What it contains | Example (packaging line) |
|---|---|---|
| Suppliers | Who or what provides the inputs | Tablet compression, warehouse, label printer supplier |
| Inputs | Materials, information, or energy entering the process | Tablets, bottles, caps, batch record, fill weight spec |
| Process | 4–7 high-level steps (the macro view, not a detailed flowchart) | Receive → Fill → Cap → Label → Inspect → Pack |
| Outputs | Products, services, or information leaving the process | Finished labeled bottles, batch records, reject log |
| Customers | Who receives the outputs (internal or external) | QC release, warehouse, sponsor (ZZMedical) |
How to build a SIPOC
- Define the process boundaries first. Identify the first step (“starts with”) and the last step (“ends with”). Everything outside that boundary is out of scope.
- Fill in Process (middle column) before Suppliers and Customers. Start with the process because the inputs and outputs are defined by the process steps, not the other way around.
- Limit process steps to 4–7. SIPOC is a macro map; detail belongs in the process map.
- Fill Outputs, then Customers. What does this process produce? Who receives it?
- Fill Inputs, then Suppliers. What does this process need? Who provides it?
Worked example: ZZMedical packaging line SIPOC
| Suppliers | Inputs | Process | Outputs | Customers |
|---|---|---|---|---|
| Tablet compression Warehouse Batch record system | Bulk tablets Empty bottles Caps, labels Fill weight spec Batch record | 1. Receive & weigh tablets 2. Fill bottles 3. Cap bottles 4. Label 5. 100% visual inspect 6. Transfer to release hold | Filled labeled bottles Batch record (packaging) Reject log | QC (release) Warehouse ZZMedical (sponsor) |
Process maps (flowcharts)
A process map shows the sequence of all steps in the as-is process, including decision points, rework loops, and handoffs. Common types:
| Map type | When to use |
|---|---|
| Basic flowchart | Single-function process; simple sequence |
| Swim-lane diagram | Multiple functions or roles share the process; shows handoffs clearly |
| Value stream map | Measuring lead time, cycle time, and value-added time; used in Lean analysis |
Standard flowchart symbols
| Symbol | Meaning |
|---|---|
| Rectangle | Process step or activity |
| Diamond | Decision point (yes/no) |
| Oval / rounded rectangle | Start or end (terminator) |
| Arrow | Flow direction |
| Parallelogram | Input or output (data) |
Common exam traps
- SIPOC is not a detailed process map. The SIPOC has 4–7 process steps. A full process map may have 30–50 steps. They serve different purposes.
- Fill process first. Many teams fill Suppliers and Inputs first and end up with inputs that don’t match the process steps. Always fill P before S and I.
- Customers include internal customers. The next step in the process, another department, or the QC lab are all valid customers for a SIPOC.
- SIPOC establishes scope, not root cause. The as-is process map in Measure reveals complexity; the SIPOC just defines the boundaries.
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