EXAMPLE: PROCESS MAPPING

Capture the sequence of activities forming the process. Use rectangular blocks for activities, single-ended arrows for sequencing. Do not use decision blocks and looping connections.

Alumina

Activity 1Potline 1AlloyingAluminum Alloys

StartElectrolysis

BauxiteElectrolysis

Potline 2Billet casting

Electrolysis

Potline 3

Electrolysis

Potline 4Rolling

ElectrolysisEnd

Aluminum

Rolled Products

Start: What triggers the start of the process?End: What are the final outputs of the process?Start-to-End Process Performance

Expect to find plans, ordersHow is it measured ?

Annual Production PlanAluminum Alloys in TonsExtraction Yield 53%

Aluminum Tonnage / Bauxite Tonnage

Rolled ProductsIn TonsProduction capacity

Aluminum Tonnage / Available capacity

Energy consumption

kW / Ton of Aluminum

Page 7

EXAMPLE: ACTIVITY MAPPING

For every activity in the process, gather specific and quantitative information in the table. Resources are like, people skills & knowledge, equipment, technology and information in addition to methods, tools, techniques and automation .

InputActivityOutput

Output rejected for not meeting requirements

Other inputs, like energy, waterUnintended output, like, solid, liquid, gaseous wate

ResourcesTools, Methods

InputOther inputsActivityResources, ToolsActivityOutputsUnintendedActivity

MethodscontrolsoutputsPerformance

AluminaElectricity 220kVPotline 1Reduction PotVoltage 10%AluminumWaste Electrolyte/99.2% Al yield

Electrolysis200 tons Max.Purity 99.2%ton of Al processedtons / input tons

Current 2%aaa tons / tonWaste Electrodes/Energy per ton

ton of Al processed

Hall-HeroultElectrolyte TempUnconverted into Al

Processxxx 5 deg Cbbb tons / ton

ElectrolyteGreen gas emission

density yyy kg/LM3/ton

Page 8

EXAMPLE: PROCESS IMPROVEMENT

Improvement processes are SYTEMATIC activities to reduce consumption, rejection, unintended outputs and improve resource availability. Generally the activities follow a Plan-Do-Check-Act (PDCA) approach. Discover the specific approaches, tools and techniques used in the organization

InputActivityOutputReduce rejects

Output rejected for not meeting requirementsincrease output

Reduce

Other inputs, like energy, waterUnintended output, like, solid, liquid, gaseous wate

consumptionReduce

ImproveResourcesTools, Methodswaste

availability

Improvement activitySystematic approach for improvementTools & techniques used

Reduce rejects, increase outputStatistical Process optimizationANOVA

Reduce dross

Reduce wasteProject Team Approach. Pollution ControlProblem solving tools. Pollution measuring

Reduce emission of PFC from Potline 1and controlling devices

Reduce consumption

Improve availabilityTotal Productive Maintenance (TPM) ActivityMTTR, MTBF studies

Potline 1 breakdown reduction