Process Mapping Brown Paper
Six Sigma Foundations
Continuous Improvement Training
Six Sigma Simplicity
Key Learning Points

Encourage Participation

Provide Tools to Identify
Issues

Understand Process
Flow
Definition, Purpose and Structure

Brown Paper is a term used to describe a
portrayal of the operation by written description of
process steps and the actual documentation
accompanying each process step.
 The method of display is to tape the written
descriptions and the document copies
sequentially left to right horizontally on a roll of
(usually) brown shipping (or craft, or butcher)
paper.
 Issues identified during the analysis are displayed
on red paper ("the reds"), explanations detailing
the process are printed on blue paper.
Definition, Purpose and Structure

Brown Papers document the processes with
"real-life" documents; this adds credibility to the
analysis.
 Assembling the Brown Paper involves all
stakeholders in the process, the Brown Paper
development process supports building a
working relationship.
 A Brown Paper presentation allows the
audience to follow the process presented, verify
the issues on the documents displayed on the
paper, and participate.
 A Brown Paper presentation stands out of the
abundance of PowerPoint™ presentations.
Definition, Structure and Purpose

There are 2 types of brown papers.


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A floor brown paper is primarily a vehicle for
mounting and displaying floor studies for ease in
presentation.
A system brown paper is an attempt to completely
display how the operation being analyzed works.
The system brown paper should be done in as
much detail as time permits; including activity
descriptions, material movement, paperwork,
computer screens, inputs, outputs, etc.; all the
things that occur in a flow.
The system brown paper is used to identify
opportunities for improvement to be addressed
during the “Project” or implementation phase.
Definition, Purpose and Structure

When assembling a system brown paper,
the goal is to have a flow of information
that is almost “self-presenting”, meaning
that other people should be able to read it
unaided and “get it”. There are several
advantages to constructing the brown
paper in sufficient detail as to be “selfpresenting”:


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Consistency in presentation
Internal information transfer
Validation from the process owner
Gathering of Information

Flow Information

When an Assessment is started, and areas
for process mapping are assigned to the
team. One of the initial activities should be to
obtain an organizational chart for the
assigned area, and get the vacation and/or
“out of town” schedule for the key
stakeholders in the area. This can be used
to develop a schedule for gathering brown
paper information, as well as preliminary and
final presentations.
Gathering Information
1.
2.
3.
4.
5.
6.
Meet with the area's Manager and obtain the basic
(general) flow.
Record the basic flow on large sticky post-it notes.
Lay these out left to right sequentially on some
brown paper. This is the first draft of the brown
paper.
Review this first draft with the Area Manager for
accuracy.
Ask the Manager to direct you to the key
stakeholders reporting to him.
Walk through the process with each key stakeholder.
Take note of any disconnects between what the
Manager thinks is happening and what actually
happens.
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Gathering Information
Tracking the Specific Example
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Problems or Issues
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To make the brown paper easier to understand, it is
always better to track the same example all the way
through.
After the detailed draft of the flow information is
completed, you will be ready to begin identifying
problems and issues, also referred to as
“opportunities for improvement”.
Area Checklists

In addition to developing the Brown Paper flows
these checklists outline some questions to be
asked in the areas to ensure completeness. Just in
case the interviewees don't point it out while you
gather the flow and detailed information
Constructing the Brown Paper
Flow:

Arrange the process in a linear flow; this means
that documents flow from left to right and there is
only one process step posted per horizontal
section of the paper. Avoid backtracking and
branching of the process display as much as
possible.
 Link process steps with arrows if appropriate. If
a process branches off, mark this with a blue
note and display the initially omitted branch in a
later section of the Brown Paper.
Constructing the Brown Paper
Headers:

Headers are printed on light to medium blue
paper. A header should include a description of
the process step or document displayed, its
frequency, and the people involved. Standardize
the header's font-size and layout throughout the
brown paper. Make sure to use the same blue
paper for all Brown Papers developed at a
project.
Constructing the Brown Paper
Explanation:

Explanation on the process steps are printed on
the same blue paper as the headings, the
"blues". Include enough detail so that a
presenter who has not worked in the area can
obtain enough information to explain the
process and explain how the issues impact
performance.
Constructing the Brown Paper
Issues:

Issues are printed in bright red paper, the "reds".
Be concise and to the point when writing the
issue. Post all studies, observations and
examples that support the issue in the vicinity of
the red for factual support.
Constructing the Brown Paper
Graphs:

Use graphs to illustrate and summarize findings
from the studies conducted or data analyzed.
Use green to indicate value-added activities,
time, or process steps, red for non-value added
parts, and yellow for non-value added essential
if applicable.
 In a vertical bar chart green would be at the
bottom and red at the top, in a horizontal chart
green would be to the left and red to the right. If
you use yellow, it would be sandwiched between
green and red.
Constructing the Brown Paper
Introductory Part and End

The first three to five feet of the Brown Paper
introduce the process map and area to the
audience. They also help the presenter to lead
into the presentation. The following
standardized structure and content facilitate this
as well as the identification of the brown paper :
Constructing the Brown Paper
1.
2.
3.
4.
Title of the process being mapped
Company Logo
Name of location
Executive Summary

Process: briefly summarize the process in a few
sentences, what it does, who it serves, why it is
important to the business, etc. on blue.
 Area Information: Summarize key information for
the area: Number of People, Hours of Operations,
Breaks/Lunch, Absenteeism Rates, Gross/Net Work
Hours, etc.
 Performance: Display the area's key performance
metrics: People, Volume, Hours, Costs, Ratios, etc.;
show trends.
Constructing the Brown Paper
5. Introduction to Brown Paper – Who, What,
When, Where
a. Picture of the product – if available
b. Organizational Chart - this is a must.
Who are the players in the process?
Who do they interact with? Who do
they report to? How do they fit into
the bigger picture?
Constructing the Brown Paper
Introductory Section to Brown Paper with Title,
Organizational Chart, Summary of Area Data and
Process Flow
Constructing the Brown Paper

Layout and Assembly of the Brown
Paper
When laying out the process flow, information,
and issues, use (unless there is a good reason
to vary) 8 ½” X 11”/ A4 sheet colored paper. The
blue sheets (describing the process steps)
should be laid out in sequential order, starting
with the earliest event on farthest left side, and
be located roughly 4” from the top.
Constructing the Brown Paper
Brown Paper with Headers, Documents, Flow and
Issues
Constructing the Brown Paper
Studies with summarized data posted on Brown Paper
Constructing the Brown Paper
Summary of the Brown Paper
At the end of the brown paper, summarize the
issues on red, develop common "themes"
between the issues to build a story.
Summarize the key studies in graphs and
quantify the issue's impact.
Constructing the Brown Paper
Summary of Issues at End of Brown Paper
Constructing the Brown Paper
Do’s and Don’ts of Brown Papers

Use One Part Number/order Number/etc
 Avoid Backwards Arrows As Much As Possible
 Be Neat
 Get The Reds
Constructing the Brown Paper

Brown Paper Review with Stakeholders
(Validation)
This preview ensures that our information sources know
what we are going to present to their management.

Presenting the Brown Paper
Presentation of the Brown Papers is typically the
conclusion of the Assessment and, at the same time, the
sales presentation for the implementation. It is very
important that we appear professional and convincing
about the issues and their impact.
Brown Paper
Six Sigma Foundations
Continuous Improvement Training