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Define Process
TheQuality
ImprovementModel
Use SPC toMaintainCurrentProcess
Collect &Interpret
Data
SelectMeasures
DefineProcess
Is
ProcessCapable?
ImproveProcess
Capability
IsProcessStable
?
Investigate &Fix Special
Causes
No
Yes
No
Yes
Define Process
Purpose:Communicate to an
individual or team a clear
understanding of the processunder study.
Establish improved andconsistent processoperations.
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Define Process
Process Components
SuppliersInputs
ProcessesOutputs
Customers
A process is any activity that converts
All processes involve Suppliers, Inputs, Outputs, andCustomers
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Define Process
Defining Processes
Communicate to an individual or ateam a clear understanding of theprocess under study.
Standardize process operations.
Identify and list Suppliers, Inputs,Outputs, and Customers.
Develop flow chart of the process steps.
Assure a common understanding ofrelated procedures.
Verify practice vs. procedure.
Why
How
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Define Process
Process Standardization
STANDARDIZATION is everyone following theprocedures the same way.
It is neither possible nor necessary to standardize allthe operations. However, crucial elements...should bemeasurable and standardized.
Misaaki Imai
KAIZEN
Are notthe optimum perfection. Are notnecessarily the current best known
methods.
Arethe agreed-upon methods.
These Procedures:
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Define Process
A Graphicaldisplay of thesteps in a process.
Purchasing Process
Standard Symbols
Process Steps
Decisions
Beginning or End Points,or Connectors between pages
Manufacturing SubmitsPurchase Order
Purchasing ContactsVendors for Pricing
Vendor Submits Bids
Vendor Delivers Goods
Manufacturing InspectsGoods
Purchasing Pays Vendor
Can VendorMeet Schedule?
No
Yes
End
Discuss Quality vs. Priceand Select Vendor
Process Flow Charts
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Define Process
Pumping
Filtration
Extrusion
String Up
Quench
Cutting
Outputs
Chip weight
Chip viscosity Chip
defects
Gels Dirt
Shutdown/rate
Process Mapping
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Define Process
What is the tool?
Graphical illustration of the process
What will the tool identify?
All value-added and non-value-
added process steps Input variables (Xs)
Output variables (Ys)
Data collection points When do you apply process mapping?
Always
Detailed Process Maps
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Define Process
1. Identify the process, its external inputsand customer outputs
2. Identify all steps in the process graphically
3. List output variables at each step4. List input variables and classify process
inputs as controlled or uncontrolled
5. Add process specifications for inputvariables
Process Mapping Steps
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Define Process
Step 1: Identify the Process andInputs/Outputs
We need to get a 50,000 ft. view of the process first
First identify the process in simple terms
Secondly we identify external inputs
o Incoming informationo Raw materials
o Personnel
o Energy requirements
Finally we identify the customer requirements
(outputs)o Identify the attributes of a correctly functioning product or service
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Define Process
Manufacturing
Fluid Bed Dryer
Rate
Temperature
Air Flow
Residence Time
Appearance (Color )
Physical Chem
Properties
Cycle Time
(plugging)Zone 3 Temp
Inputs Outputs
Order EntryPhone
FAX
Price
Availability
Confirmation of
Order
Promise Date
Order number
Inputs Outputs
Non- Manufacturing
Step 1: Examples
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Define Process
Include all value-added and non value-added steps
Process steps, inspection/test, rework, scrap points
Manufacturing
Answer Phone
Greet customer
Determine parts needed
Identify need date
Identify ship to address
Identify price
Identify shipment method
Internal Information
Get internal P/N
Determine terms
Identify lead time
Complete order
worksheet
Order Entry
Input information
Print order confirmation
Determine ship date
Review order
Order Confirmation
FAX confirmation to
customer
Verify manufacturing
receipt of order
Non-Manufacturing
Mixing
Water andMetals
Preparation
Extrusion
Extrudethrough die
Dryer
CalcinerNADM
SolutionPreparation
Impregnation
Metalsaddition
Fluid Bed
Dryer
Finalpreparation /
appearance
issues
Material
drying, surface
area issues
Step 2: Identify All Steps in the Process
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Define Process
Include both process and product output variablesManufacturing
Outputs Outputs
TV of Mix -
Quality
Check
around
extrusion
TV of Mix -
Quality
Check
around
extrusion
Surface Area
Pore Volume
Appearance
pH
Temp
Specific Gravity
Clarity
Appearance
(Color,
Wetness)
Appearance(Color)
Physical
Chemical
Properties
Cycle Time
(plugging)
Zone 3 Temp
Mixing
Water and
Metals
Preparation
Extrusion
Extrude
through die
Dryer
Calciner
Material
drying, surface
area issues
NADM
Solution
Preparation
Impregnation
Metals
addition
Fluid Bed
DryerFinal
preparation /
appearance
issues
Step 3: List Key Output Variables
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Define Process
Include both process and product output variables
Prompt
answer
Live body
Part number
Availability Need date
Customer
number
Order
worksheet
Pricing
Non-ManufacturingOutputs
Answer Phone
Greet customer
Determine P/N
Identify need date
Identify ship to address
Identify ship method
Internal InformationGet internal P/N
Determine terms
Identify lead time
Complete order
worksheet
Outputs
Order in
computer
All line
items
complete
Correct info
Promise
date
Order
number
Printed
confirmation
Order
confirmation
to customer
Order to
production
Order Entry
Input information
Print order confirmation
Determine ship date
Review order
Order Confirmation FAX confirmation to
customer
Verify manufacturing
receipt of order
Step 3: List Key Output Variables
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Define Process
List all key input variables and classify them as Controlled inputs
Uncontrolled inputs
Control led Inpu ts: Input variables that can be changed to see
the effect on output variables
Sometimes called knob variables
Uncontrol led Inpu ts: Input variables that impact the output
variables but are difficult or impossible to control (may also
be controllable, just not under control currently)
Example: Environmental variables such as humidity
Crit ical Inp uts: Input variables that have been statistically
shown to have a major impact on the variability of the output
variables
Step 4: List and Classify Key Input Variables
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Define Process
Manufacturing
Outputs Outputs
TV of Mix -
Quality
Check
around
extrusion
TV of Mix -
Quality
Check
around
extrusion
Surface Area
Pore Volume
Appearance
pH
Temp
Specific Gravity
Clarity
Appearance
(Color,
Wetness)
Appearance
(Color)
Physical
Chemical
Properties
Cycle Time
(plugging)
Zone 3 Temp
Mixing
Water and
Metals
Preparation
Extrusion
Extrude
through die
Dryer
Calciner
Material
drying, surface
area issues
NADM
Solution
Preparation
Impregnation
Metals
addition
Fluid Bed
DryerFinal
preparation /
appearance
issues
Total Rate C
Mixer Speed C
Al2O3 Qual U
Rec Comp U
Ext Rate C
Die Wear U
Ext RPMs C
Die Change U
Temperature C
Rot speed C
Draft C
Feed Rate C
Drying air U
Inputs Types Inputs Types
Nitric Acid C
H2O2 C
Water C
ADM C
Hold Time UAgitation C
Phos Acid C
Nozzle Type C
Spray Time C
Water C
Moly C
Nickel C
Base C
Temperature C
Rate C
Air Flow C
Res Time C
Process Mapping Examples
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Define Process
Non-Manufacturing
Outputs
Answer Phone
Greet customer
Determine P/N
Identify need date
Identify ship to address
Identify ship method
Internal Information
Get internal P/N
Determine terms
Identify lead time
Complete order
worksheet
Order Entry
Input information
Print order confirmation
Determine ship date
Review order
Order Confirmation
FAX confirmation to
customer
Verify manufacturingreceipt of order
Inputs Type
Order
worksheet
Computer
entry screens
Lead time
information
from mfg
Shipmentmethod
Printed
confirmation
sheet Production
schedule
Customer
contact info
Production
contact info
Confirmation
procedure
U
C
U
C
C
U
C
C
C
Inputs Type
Information
from customer
Greeting script
Answering
procedure
Telephone
system
Cross
reference for
P/Ns
Order
information
Plant loading
information
Order
worksheet
form
Pricing
algorithm
C
C
C
U
C
U
U
C
C
Prompt
answer
Live body
Part number
Availability
Need date
Customer
number
Orderworksheet
Pricing
Outputs
Order in
computer
All line
items
complete
Correct info
Promisedate
Order
number
Printed
confirmation
Order
confirmation
to customer Order to
production
Process Mapping Examples
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Define Process
Controlled Input
VariableTarget
Upper
Spec
Lower
Spec
Die Wear ? ? ?
Solvent Type ? ? ?
Ram Speed ? ? ?
Clamping Force ? ? ?
For input variables identified as Controlled and CriticalInputs, we can add the operational specifications andtargets for these variables
This information is the beginnings of the Control Plan!
Step 5: Add Specifications for Inputs
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Define Process
Using Process Maps to Evaluate
Processes
Understand customer/supplier relationships
Discover unnecessary steps Achieve agreement on process
Everyone understands their role
Provides inputs to Cause and Effects Matrix
Provides inputs to Control Plan Summary
Provides inputs to Capability Summary
Excel template: Process Map Master.XLS
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