basics of defining processes

7/27/2019 Basics of Defining Processes

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2-1

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

Email

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 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


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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2-15

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 method

Internal Information

Get internal P/N

Determine terms

Identify lead time

Complete order

worksheet

Order Entry

Input information


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

basics of defining processes

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