Most process maps get built once, satisfy an audit, and die in a shared folder. The moment the org chart shifts or a system changes, the map is wrong — and everyone quietly stops trusting it. This page is our attempt to build something that stays true, because people are actually using it and correcting it.
Every process on this page starts as a SIPOC — Suppliers, Inputs, Process, Outputs, Customers — before it gets detailed. A SIPOC forces a team to agree on scope in five or six boxes before anyone argues about task-level mechanics. The useful trick is to fill it out backwards: Customers first, then Outputs, then Process, then Inputs, then Suppliers. Naming who the work is for and what they actually need, before mapping the steps, keeps the process honest to its purpose instead of just describing what people happen to do today.
A map only works if two people read it the same way. We're deliberately not using strict BPMN — Business Process Model and Notation, the ISO/IEC 19510 standard — here. BPMN uses formal pools and swimlanes, precise task/event shapes, and exact gateway logic (exclusive, parallel, inclusive) to spell out branching decisions without ambiguity. It's the right tool when a systems integrator needs to wire an actual workflow engine to it, but it reads like an engineering spec to everyone else. Instead we pair the SIPOC scope with GTC's stage-gate structure and plain process-owner, input/output, and measurement fields — closer to the spirit of ISO 9001's "process approach," which cares less about which shape you draw than about whether ownership, inputs/outputs, and KPIs are actually documented for every step.
A static map can describe a process. A live one can drive change — because most change efforts fail for the same reason: someone updates a policy without seeing what it touches upstream or downstream. A current map makes handoffs and dependencies visible before they become a rollout problem. It's also how you find real automation and AI candidates — you can't target a bottleneck, a manual re-entry step, or an RPA opportunity you can't see mapped out. And when a change does land, the map instantly scopes who and what systems are affected, which is most of the work of planning a rollout.
The Live Status panel above the SIPOC grid pulls real counts directly from our R&D project database — not a snapshot from the last time someone remembered to export it. The feedback flyout on the right edge lets anyone looking at a step flag that it's wrong, out of date, or missing something, and it lands in a tracked queue our team actually reviews — logged in automatically through Azure AD, no manual sign-off needed. That's the whole idea: the map corrects itself because the people doing the work are the ones maintaining it.
The near-term roadmap is to make each step clickable — click a high-level box here and drop straight into the detailed procedure, the system it runs in, and the metric that tracks it, rather than making someone go find a separate SOP. Combined with the feedback loop already live on this page, that turns this from a diagram you look at once into an operating reference the teams actually return to.
Temporary — help us build the source of truth. Pick the page this is about, describe what you'd like changed, and hit submit. A Manager/Senior Manager, R&D reviews all submissions. This panel will be removed once the Future State revision ships.
Logged in via Azure AD — your name/email is attached automatically.
Feedback Received — thank you.
Green Tokai Co., Ltd. (GTC) — R&D Department, and Kick-Ass Innovations (KAI), an in-house business line incubated by R&D (not yet a separate legal entity — Current State). Built on a SIPOC + Stage-Gate framework, GTC's standard process-map format.
Covers how an idea becomes a GTC R&D project: intake via the R&D Project Proposal form, system-of-record tracking in Airtable, cross-functional ranking, and progression through the 5-gate stage-gate review used to judge concept, prototype, internal development, final development/marketing, and production release.
Any associate or department identifies a cost-savings, quality, automation, new-model, or new-sales opportunity worth evaluating.
Standard intake channel: proposal title, application, value/objective, description, primary objective(s), rankings (new sales potential, cost savings, feasibility, investment requirement), estimated cost, funding source, staff/hours needed, risks & dependencies, strategic alignment, urgency, target timing, and supporting files.
Proposal is logged as a new record in the Airtable "R&D Project" table and issued a Project # (e.g., RD00xx). Alternate entry paths exist for phone, email, or support-ticket-originated ideas, but Jotform → Airtable is the standard, preferred path.
Are application, value/objective, and rankings sufficient to route the idea?
R&D staff, Senior Manager, or Manager, R&D assign Project Category & Sub-Department, designate Champion(s) and Support Team by discipline, and link any applicable Tax Benefit category for future R&D credit substantiation.
How should this project be prioritized?
Gate Judge reviews rankings, feasibility, and concept viability.
Champion and Support Team build tasks and milestones, develop the initial prototype, and document test results before returning to the Judge for a gate decision (Approve / Hold-Revise / Reject).
Findings and prototype are presented internally (Steering Committee / relevant department heads); feedback incorporated; Judge renders gate decision.
Design finalized; marketing/sales collateral prepared where relevant; cost, savings, and tax-benefit figures validated; Judge renders final pre-production decision.
Final gate judgement authorizes hand-off to GTC's owning department (Engineering, Production, Sales, or KAI) for full-scale production or implementation — the same concept → prototype → hand-off arc used across every GTC R&D project.
Concerns are logged with severity/resolution; milestones and tasks are tracked to plan vs. actual; staff notes and history maintain a full audit trail for every project.
ACTION set to COMPLETED; realized cost savings/revenue documented against the original Value/Objective; R&D tax-credit documentation finalized; project archived as a continuous-improvement reference.
How the two maps connect: KAI began as R&D Project RD0012 ("KAI-GTC uniforms in-house mfg / embroidery") — concept → prototype → hand-off from R&D to ongoing operation under GTC, the same arc every R&D project follows through the Gate process above. New product and Business Workflows & Intelligence ideas surfacing inside KAI today still re-enter the R&D pipeline (Step 2, Jotform) for formal evaluation before further investment; KAI's eventual move to full independence (Future State) will follow this same gated process.
KAI began as R&D Project RD0012 and today operates as a business unit inside GTC R&D — not yet a separate legal entity. It runs four customer-facing lines — Shirts, New Products/Services, Media Support/Services, and Business Workflows & Intelligence (consulting/sales of the apps, AI, and workflow systems GTC has built in-house) — plus internal digital signage support, produced in-house (embroidery, 3D printing, wide-format) or coordinated through an outsourced print portal. Current State: all KAI sales transactions are captured in KAI's online ecommerce systems and migrated into GTC's Plex (ERP); all KAI expense transactions are booked directly through Plex. KAI is still staffed and governed through R&D, and financially runs through GTC's books — see the Current/Future State note above; a Future State revision will reflect KAI as a fully independent legal and financial entity.
Four intake channels: the public storefront (Shirts, New Products/Services), the internal outsourced-print/media portal (brochures, signage, personal orders), a direct internal request for digital signage/media content, or a direct engagement request for Business Workflows & Intelligence consulting (apps, AI, workflow automation).
Order/job is triaged against current queue, equipment availability, and KAI's revenue-line targets.
Embroidery, 3D printing, wide-format, and digital signage are KAI's in-house capabilities.
Quote/price is set using KAI's cost-plus model — direct expense ratio by line (Shirts ≈28.25%, New Products ≈33.3%, Media Support ≈75%) — referencing the internal Pricing Strategy and retail-vs-wholesale margin sheets; shipping is added at checkout, not embedded in the item price.
Does the produced or vendor-delivered item meet KAI/brand standards (layout, color, finish, resolution)?
Pick, pack, and label; ship via KAI's own FedEx account or deliver internally for signage/media requests.
Consumable/blank stock levels updated; storefront listings and availability adjusted as needed.
Sales are captured in KAI's ecommerce platform and migrated into GTC's Plex (ERP); all KAI expenses are booked directly in Plex. Current State: KAI is not yet a separately capitalized legal entity — all financial activity flows through GTC's books.
R&D Technician reports storefront traffic, conversion, top sellers, and margin by line to the Senior Manager, R&D (or Manager, R&D), against KAI's business plan targets.
Product or process ideas generated inside KAI (new SKUs, new equipment, new capabilities) are submitted back through the GTC R&D Project Proposal for formal evaluation before further investment — closing the loop with the R&D map above.
Direct links to the systems referenced throughout both process maps. Internal links require standard company sign-in / VPN access.
Jotform used by any associate/department to submit a new R&D idea.
R&D Project Proposal ↗Airtable base tracking every project, gate, task, milestone, and concern.
R&D Project Database ↗Internal-facing ordering portal for outsourced print & media jobs (production, admin, purchasing, sales, marketing, and personal staff orders).
Media / Print Portal ↗Manufacturing ERP referenced across R&D resourcing, engineering, and quality processes.
Plex ERP ↗GTC's growing practice for the consulting & sales side of the apps, AI, and workflow systems built in-house. Every engagement follows the same arc as an R&D project — concept, internal prototyping inside KAI/R&D, then hand-off to GTC for full-scale delivery — with examples already in production today: this process map, the R&D Airtable system, and KAI's ecommerce/production tooling.
ONLINE SHOWCASE COMING SOON — engagements available now