Basics of defining processes

1. 2-1
Define Process
The
Quality
Improvement
Model
Use SPC to
Maintain
Current
Process
Collect &
Interpret
Data
Select
Measures
Define
Process
Is
Process
Capable
?
Improve
Process
Capability
Is
Process
Stable
?
Investigate &
Fix Special
Causes
No
Yes
No
Yes
Define Process
Purpose:
•Communicate to an
individual or team a clear
understanding of the process
under study.
•Establish improved and
consistent process
operations.

2. 2-2
Define Process
Process Components
Suppliers
Inputs
Processes
Outputs
Customers
 A process is any activity that converts
 All processes involve Suppliers, Inputs, Outputs, and
Customers

3. 2-3
Define Process
Defining Processes
 Communicate to an individual or a
team a clear understanding of the
process under study.
 Standardize process operations.
 Identify and list Suppliers, Inputs,
Outputs, and Customers.
 Develop flow chart of the process steps.
 Assure a common understanding of
related procedures.
 Verify practice vs. procedure.
Why
How

4. 2-4
Define Process
Process Standardization
STANDARDIZATION is everyone following the
procedures the same way.
“It is neither possible nor necessary to standardize all
the operations. However, crucial elements...should be
measurable and standardized.”
—Misaaki Imai
KAIZEN
 Are not the optimum perfection.
 Are not necessarily the current best known
methods.
 Are the agreed-upon methods.
These Procedures:

5. 2-5
Define Process
A Graphical
display of the
steps in a process.
Purchasing Process
Standard Symbols
Process Steps
Decisions
Beginning or End Points,
or Connectors between pages
Manufacturing Submits
Purchase Order
Purchasing Contacts
Vendors for Pricing
Vendor Submits Bids
Vendor Delivers Goods
Manufacturing Inspects
Goods
Purchasing Pays Vendor
Can Vendor
Meet Schedule?
No
Yes
End
Discuss Quality vs. Price
and Select Vendor
Process Flow Charts

6. 2-6
Define Process
Pumping
Filtration
Extrusion
String Up
Quench
Cutting
Outputs
Chip weight
Chip viscosity Chip
defects
Gels Dirt
Shutdown/rate
Process Mapping

7. 2-7
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 (X’s)
 Output variables (Y’s)
 Data collection points
 When do you apply process mapping?
 Always
Detailed Process Maps

8. 2-8
Define Process
1. Identify the process, its external inputs
and customer outputs
2. Identify all steps in the process graphically
3. List output variables at each step
4. List input variables and classify process
inputs as controlled or uncontrolled
5. Add process specifications for input
variables
Process Mapping Steps

9. 2-9
Define Process
Step 1: Identify the Process and
Inputs/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 information
o 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

10. 2-10
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 Entry
Phone
FAX
Email
Price
Availability
Confirmation of
Order
Promise Date
Order number
Inputs Outputs
Non- Manufacturing
Step 1: Examples

11. 2-11
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 and
Metals
Preparation
Extrusion
Extrude
through die
Dryer
Calciner
NADM
Solution
Preparation
Impregnation
Metals
addition
Fluid Bed
Dryer
Final
preparation /
appearance
issues
Material
drying, surface
area issues
Step 2: Identify All Steps in the Process

12. 2-12
Define Process
 Include both process and product output variables
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
Dryer
Final
preparation /
appearance
issues
Step 3: List Key Output Variables

13. 2-13
Define Process
 Include both process and product output variables
• Prompt
answer
• Live body
• Part number
• Availability
• Need date
• Customer
number
• Order
worksheet
• Pricing
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
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

14. 2-14
Define Process
 List all key input variables and classify them as
 Controlled inputs
 Uncontrolled inputs
Controlled Inputs: Input variables that can be changed to see
the effect on output variables
Sometimes called “knob” variables
Uncontrolled Inputs: 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
Critical Inputs: 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

15. 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
Dryer
Final
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 U
Agitation 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

16. 2-16
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 manufacturing
receipt of order
Inputs Type
• Order
worksheet
• Computer
entry screens
• Lead time
information
from mfg
• Shipment
method
• 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/N’s
• 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
• Order
worksheet
• Pricing
Outputs
• Order in
computer
• All line
items
complete
• Correct info
• Promise
date
• Order
number
• Printed
confirmation
• Order
confirmation
to customer
• Order to
production
Process Mapping Examples

17. 2-17
Define Process
Controlled Input
Variable
Target
Upper
Spec
Lower
Spec
Die Wear ? ? ?
Solvent Type ? ? ?
Ram Speed ? ? ?
Clamping Force ? ? ?
 For input variables identified as Controlled and Critical
Inputs, we can add the operational specifications and
targets for these variables
 This information is the beginnings of the Control Plan!
Step 5: Add Specifications for Inputs

18. 2-18
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