The development of processing maps using the dynamic materials modelling (DMM) approach is a widely used method for choosing the appropriate process parameters for the thermomechanical processing of any material. A processing map depicts the variation of metallurgical power dissipation efficiency (η) and the material stability with changes in temperature and strain rate for a constant strain. Our study discovered that the conventional methodology to generate processing maps involved incorrect assumptions and computational errors which resulted in the production of unhealthy products using process parameters thus derived. To overcome this, we have designed a novel, efficient, and error-free algorithm to develop the processing map of any material using accurate domain-splitting and approximation techniques. We have also proposed the new binary instability parameter (β) that incorporates all instability conditions such that process parameters that should be avoided can be easily identified. This new algorithm will result in the production of healthy components using suitable process parameters.