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Table of Contents

Executive Summary .......................................................................................................................... 2

1.0                  Background ................................................................................................................ 3

2.0                  Work Methodology .................................................................................................... 4
2.1                         Methodology Used ............................................................................................................ 4
2.2                         Cementa Research AB ....................................................................................................... 4
2.2.1                           The Company ............................................................................................................. 4
2.2.2                           Services Offered ......................................................................................................... 4
2.2.2.1                             Product Control................................................................................................... 4
2.2.2.2                             Product Development ......................................................................................... 4
2.2.2.3                             Equipment and Machinery .................................................................................. 4
2.2.2.4                             Process Development.......................................................................................... 4
2.2.2.5                             Quality Control and Environmental Issues ......................................................... 5

3.0                  Theory Used............................................................................................................... 6
3.1                         Process ............................................................................................................................... 6
3.2                         Process Classifications ....................................................................................................... 6
3.3                         Process charting ................................................................................................................. 7
3.4                         Flow chart .......................................................................................................................... 7
3.5                         Six Sigma ........................................................................................................................... 8

4.0                  Results ....................................................................................................................... 9
4.1                         CEN and EN-197 ............................................................................................................... 9
4.2                         Stakeholders ....................................................................................................................... 9
4.3                         Process Descriptions .......................................................................................................... 9
4.3.1                           Sample Registration ................................................................................................... 9
4.3.2                           Testing ...................................................................................................................... 10
4.3.2.1                              Physical Testing ................................................................................................ 10
4.3.2.2                              Chemical Testing .............................................................................................. 10
4.3.3                           Reporting .................................................................................................................. 10
4.4                         Measurable Parameters .................................................................................................... 10
4.5                         Other Information ............................................................................................................ 13
4.5.1                           Management Processes............................................................................................. 13
4.5.2                           Support Processes ..................................................................................................... 14

5.0                  Proposal ................................................................................................................... 15

6.0                  Reflections ............................................................................................................... 16

7.0                  References ............................................................................................................... 17



Annex 1 .......................................................................................................................................... 18
Annex 1.1 ....................................................................................................................................... 19




                                                                             -1-
Executive Summary
Process management seems more of an engineering tool to only be used in a manufacturing industry
but it can be used effectively in management to map a process and discover problem areas (if any) or
be used as a stimulus to improve the system. MIM students utilized the tool in dispatch testing to
describe processes and analyze measurable parameters in the process. After thorough analysis of
activities in two departments of Cementa Research AB (CRAB), chemical and physical departments,
they discovered a few some areas which can be improved relative to delivery time.

However, the project was undertaken at a very tricky period. Two events had overtaken CRAB that
have and will continue to have tremendous impact on their operations. One of them is the loss of
their major client, Maxit and the other one is the global economic recession. Thus, the workload has
been reduced and the pressure has disappeared.




                                               -2-
1.0    Background
MIM students studying Applied Process Management (APM) at Gotland University were
compulsorily commissioned to undertake a group project running simultaneously alongside APM
lectures. The overall aim was to marry theory with practical, divorce of which would produce half-
baked students out of this academic oven.

The specific area of focus was selected by the course instructor and the underlying tasks thereof.
Different groups were allocated to different organizations but all of them were charged with studying
a given process in the organization, preparing an overall process chart and proposing any
improvements that can be made.

Group IV was appointed to undertake a process charting at Cementa Research AB. Group meetings
and company visits were made. Group members’ and team leaders’ knowledge, creativity,
experiences and tireless efforts in this project are conferred herein as a project report.




                                                -3-
2.0    Work Methodology
Here we describe the methodology that was used in undertaking the whole exercise.

2.1 Methodology Used
The project team (leaders and crew) held several meetings to plan for the project. The crew had to
revisit theory on process charting and dig out some information from the firm’s website prior to
visiting CRAB on 13th February 2009. During the visit, the team was shown the whole process and
then it was treated to a presentation about the process and the firm. Another visit was taken on 7th
March 2009, where the project crew gained in depth knowledge about the chemical and physical
analyses that are conducted. Consolidation concomitant to the visits and several team meetings have
given birth to this report.

2.2    Cementa Research AB1

       2.2.1      The Company
       This is a research company owned by Cementa AB which operates in Sweden under
       Cementa Heidelberg Cement Group. It employs 45 people who work in five production
       groups namely; chemical analyses, physical testing, cement investigation, cement premix and
       software development. These production groups work in coordination with the MD,
       Secretary and a Technical Department.

       Cementa Research AB (CRAB) was accredited as a testing laboratory by Swedac (Swedish
       Board for Technical Accreditation) for almost 150 testing methods. The company is situated
       in Slite where it has a laboratory which is well equipped with modern facilities and
       equipment which is used to undertake consultancy services, analyses and to bring new
       knowledge into Heidelberg Cement.

       2.2.2      Services Offered
       Though its main activities are in mineral based materials, it goes over and above this. It
       works with fuels, drinking water and waste water; environmental analyses, measurements,
       environmental audits and development of environment management system of a company.
       The Slite laboratory is equipped to undertake organic and inorganic chemistry functions as
       well as physical testing. Its competence revolves around microbiology, theology and indoor
       environment.

       In mineral based building materials it has four main activities namely; product control,
       product development, quality and environmental techniques and improvements in the
       processing industry.

       2.2.2.1    Product Control
                  In product control area, they use different methods or standards to control the
                  quality of cement and concrete.




                                               -4-
2.2.2.2   Product Development
          Product development ensures quality of cement and concrete with respect to
          different dimensions like durability of building materials, the mixing quantity of
          different materials etc. Product development contributes in continuous
          development towards better and more specialized products and it enhances the
          competitive capability of the cement plant and helps in increasing its demand as
          compared to its substitutes.

2.2.2.3   Quality Control and Environmental Issues
          In quality and environment, Cementa AB runs different quality projects in the
          field of cement and concrete production. It helps its customers in building quality
          systems for certification and it also performs some type of quality audits.

2.2.2.4   Process Development
          Leveraging on experienced employees, in process development, it performs
          different comprehensive consultancies. It helps in improving products or
          productivity to make the production more economical.

2.2.2.5   Equipment and Machinery
          Cementa Research AB uses a lot of equipment in the following categories;
          chemical analyses, particle size distribution and surface area measurement,
          microstructure, cement testing equipment, concrete testing equipment, coal
          testing, air and gas analyses, climate equipment and computer system.

          It also produces quality handbooks, quality documents which are adjusted time
          and again to guide and help them in offering their services to customers.




                                       -5-
3.0    Theory Used
The theory on which the project was based is discussed below.

3.1    Process

       Process originate from the ‘processus’ and ‘procedere’ which are all Latin words which
       mean ‘advancement’ or ‘move ahead’. 2 The concept of process can be applied in various
       aspects or fields but in this project, the concept is narrowed to management. Hence, it is
       defined as a set of activities with a specified beginning and end, which, using the resources of
       an organization, repeatedly adds value to a measurable object from a supplier to a
       predetermined measurable result to a customer.3



                       Interface
          Supplier                     Process                           Customer/Stakeholder


               Input                                                         Output


                                          Value-adding




                                     Resources


         Figure 3.1.1      Process Diagram (From Bergman, B. & Klefjö, B. 2007)


3.2    Process Classifications

       Processes can be distinguished by their aims. Using this classification, three types of
       processes are realized, main, support and management processes.

       Main processes are core processes, whose tasks are geared towards satisfying the external
       customers’ needs, creating value for them and improving the products delivered by the
       organization. Support processes are these are feeder processes because they feed resources
       into the main process. Management processes are determinant processes in that they set
       targets, devise strategies and work out improvements in the other processes in the
       organization. In a process there are both internal and external customers. The internal
       customers are the recipients of the output of the other departments which use them as
       primary inputs in their activities while external customers are those that are outside the
       organization and they are usually the ones that matter a lot because all the departments and
                                               -6-
the main process using the organizational resources like information and energy work to
      serve and satisfy their needs.3

3.3   Process charting
      Process charting is a graphical method of showing an array of steps through which input is
      converted to output. A process chart defines ownership, customer and boundaries. It helps in
      finding control points, in this way it easy to establish measurements and show results.

      Different process models can be used by any organization as a way of identifying
      performance measurements and examining the process in detail to identify areas of possible
      improvements. Proposed organizational system model, proposed basic process model, and
      generic process model are commonly used for process measurements.


                                         Main process


              Activity A                 Activity B              Activity C                Activity D




                      B1                 B2                 B3


                                                                 B3a            B3b            B3c


      Figure 3.3.1          Process Diagram (From Bergman, B. & Klefjö, B. 2007)

3.4   Flow chart

      A flow chart is a series of activities that are connected to one another sequentially determined
      by appropriate decisions that are required to proceed to them. It can be used to find the
      process improvements in detail. Flow charts are useful diagrams showing the steps of a
      process clearly and how processes work. It is easy to understand the whole process step-by-
      step. The organization can find what really happens next in the process; what the next step is;
      what errors and wastes occur and where the process should be improved from start to the
      end. Excellent flow charts show us every important detail of main process, sub process,
      activities, and work tasks clearly.
                                     Y                                      Y
          Start                 If            Activity            If                Activity            Stop

                                                      N
                                                            Y                   Y
                           No                 Activity           Activity              Activity

                                                      N
                                                                    Stop

                                                          -7-
Figure 3.4.1    Flow chart (Adapted from the Applied Process Management lecture of
                          20-01-2009 at Gotland University)

3.5   Six Sigma

      The essence of survival of a firm lie in the satisfaction and retention of customers. Customer
      satisfaction is the duty of the overall company not just of the marketing department. The
      marketing department can be the overall overseer of meeting a standards of customer
      satisfaction. Customer seek consistency. They are loyal to a firm that offer a consistent
      product or service. Six sigma is one of the tools that can be used to measure variations in
      various processes that lie in the path of adding value to an input all the way to delivering an
      output into the hands of a customer. Variations in processes are definitely affect the quality
      of the product and will eventually be passed on to the customer.

      Six Sigma was originally developed by Motorola in the 1980s as a quality improvement tool.
      Basically it was used to reduce the number of defects and unwanted variations in the
      organizational process. Six Sigma provides a systematic methodology to process
      improvement. When companies are using this the Six Sigma approach to quality
      improvement, “process flow” and “standard” are the most important concepts. They aim to
      achieve the possible and necessary improvements. The steps that are followed in this
      approach are abridged to DMAIC which stands for Define Measure Analyse Improve and
      Control. DMAIC can be easily understood in a numerical layout as below: 9

      -    Define high-level project goals, and the current process
      -    Measure key aspects of the current process and collect relevant data.
      -    Analyze the data to verify cause-and-effect relationships. Determine what the
           relationships are, and attempt to ensure that all factors have been considered.
      -    Improve or optimize the process based upon data analysis using techniques like Design of
           experiments.
      -    Control to ensure that any deviations from target are corrected before they result in
           defects. Set up pilot runs to establish process capability, move on to production, set up
           control mechanisms and continuously monitor the process.”




                                               -8-
4.0    Results
The findings of the project follow hereinafter.

4.1    CEN and EN-197
       Cement is a hydraulic binder. It is finely ground inorganic material that forms a paste when
       mixed with water. The paste sets and hardens by means of hydration reactions and processes
       but after hardening, it retains its strength and stability even under water. 1 Sweden is a
       member of CEN (Comité Européen de Normalisation) which European Committee for
       Standardization. CEN members are bound to comply to EN 197-1 which is the European
       Standard about composition, specifications and conformity criteria for common cements. 4

       Cement has to conform to EN 197-1 in mechanical, physical, chemical and durability
       requirements. Mechanical requirements entail standard and early strength while physical
       requirements focus on initial setting time and soundness. Chemical requirements revolve
       around composition of the in terms of elements like hydrochloric acid, sodium carbonate,
       sulfate and chloride while durability looks at the cements ability in terms of frost resistance,
       chemical resistance and protection of reinforcement.5

       Therefore, to check this conformity, cement has to be tested, hence the existence of Cementa
       Research AB.

4.2    Stakeholders
       The stakeholders or clients that benefit from this process or organisation are Cementa Slite
       Plant and Cementa Marketing Department. The process is called dispatch testing meaning
       that they get a sample from the lot that is going to be dispatched and test it. Apart from
       controlling quality of final product, (thus physical and chemical properties) and ensuring
       SPC, this process is also undertaken to maintain product database for Cementa and Cementa
       customers.6

       The process for checking conformity has never been mapped so mapping process
       descriptions and showing process ownership will be an improvement and so will be
       shortening delivery time so that it is shorter or good enough for the customer. 7

4.3    Process Descriptions8

       4.3.1       Sample Registration

                   Sample registration sometimes starts with homogenization or ends with
                   homogenization. It just depends on the officer; he can homogenize it first or do
                   the other steps first and lastly homogenize it. Depending on what choice he has
                   made, he goes to mark the container of the sample and then check what test is
                   required from a check sheet. Previously, they did not have to check the kind of
                   test needed because for every sample, they were doing the full test, but now, due
                   to an economic slump, they have to choose which sample has to go through a full
                   test or a reduced test or just a physical test. He records the sample details into a
                   table and record more details about the sample in the computer. After this, an air
                   tight, sealable small storage bag is marked and some amount of the sample is put
                                                  -9-
in the bag and stored in a wooden box ready for collection by the chemical
                   department.

       4.3.2       Testing

                   4.3.2.1       Physical Testing
                   Physical testing is performed in the physical department. They take part of the
                   sample from the dispatched container and mix it with either water or sand or just
                   use it the way it is. After the physical test, they record the results on a sheet of
                   paper and then transfer them to the computer.

                   4.3.2.2       Chemical Testing

                   When the sample details are recorded in the computer, it registers in the chemistry
                   department computers that there is a new sample which needs to be analyzed.
                   They get the sample from the physical department and check in the computer
                   what kind of test (thus, either full or reduced) is supposed to be performed on this
                   particular sample. They later do a chemical homogenization as a way of preparing
                   the sample and then they do a Spectra ICP Test, and then Chrome analyses. After
                   these, they get the preliminary results and match those results with the standards.
                   If the results are out of limit of the standards, then, they redo the test. Otherwise,
                   they enter the results in the computer using LIMS (Laboratory Information
                   Systems).

      4.3.3        Reporting

                   When the results are entered into the LIMS, they are checked by the Cement
                   Investigation Department. If they are within the required parameters, they are
                   released and published to the server so that the client can access them online.

(For a complete illustration of the above processes, please refer to Annex 1)

4.4    Measurable Parameters
       The only measurable parameter which can be used as a basis for improvement is delivery
       time, thus, the time taken from receiving the sample to releasing the report to the client. The
       chemical and physical department activities were followed closely to determine the delivery
       time.

       To start with, there is delivery time is set by the client. That is to say, the client put a
       reasonable demand as to when they want the results. To follow this parameter correctly and
       to analyze the activities deeply, Cementa AB Marketing department will be used as the only
       client. Cementa AB can bring a sample that has to be analyzed and be reported on and it
       specifies a delivery time.

       Basically, this is what will be involved to reach that end:
       1. Sample Registration
          a. The sample container is marked with the sample number (continuation of numbers
             derived from a LIMS)
                                                 - 10 -
b. The sample is taken for homogenization: Here the container is put on a machine which
      rotates together with the sample container and continually shaking the contents inside
      for 30 minutes.
   c. A sheet of paper is checked to see what kind of test is supposed to be done on this
      sample and then the sample details are recorded on the same sheet
   d. The sample details are recorded into LIMS
   e. Activities b, c and d can take approximately five minutes, thus, thirty-five minutes
      together with activity b. However, the reader should note that the sample is not put in a
      homogenizer and the officer stands there for thirty minutes waiting for it. He continues
      with other tasks.
   f. A sealable, air-tight A6 plastic bag is marked with the sample details and two
      tablespoonfuls of the sample are placed into this bag and put into a box ready to be
      collected by the physical department.

2. Physical Testing
   Several physical tests can be performed on this sample but the priority ones include
   a. Fann: Here a part of the sample is mixed with water to make slurry and the slurry is
      tested for its thickness using a Viscometer. The resistance recorded on this machine is
      the thickness. This figure is recorded immediately on a sheet of paper to be transferred
      later to the computer. This takes approximately one and a half hours.
   b. Vicat vatten (setting time): Here, part of the sample is mixed with water to form slurry
      and then put in water and a needle from a gadget comes and pierces into this slurry at
      intervals set by the officer. It continues to jab into this slurry until it cannot sink into it
      more than 22 mm. This may take from 20 to 180 minutes.
   c. Laser: Here less that a teaspoonful of the sample is taken and spread on a microscope
      like machine which calculates the size of the particles of the cement. This takes less
      than 30 minutes.
   d. Blaine is a different form of a laser analysis
   e. Determination of strength: Here, part of the sample is mixed with sand in a machine for
      30 minutes. From the ‘mixer’ it is spread into a ‘molder’ which is placed into a
      machine which lifts it every 2.5 seconds. After fifteen minutes, it is removed and the
      brick(s) formed are placed in a moist chamber for one day and removed the following
      day. After removing the brick, depending on the type of analysis, it is subjected to
      further tests. For example, if it is 1 day strength, it is immediately taken to a machine
      that crushes it. If it is 2 days strength, then it is placed in water for two days and after
      that is crushed. If is a 28 days strength, it is placed in water for 28 days and then
      removed and crushed.

   The results for each test are recorded on a paper first then transferred into LIMS. Thus,
   when a test is completed, the results can go into LIMS immediately, subject to how busy
   the officer is. The department is manned by two officers and occasional assistance from
   one staff from chemical department.

3. Chemical Testing
   a. Collection of sample: When the sample details are recorded n LIMS, it registers in the
      chemical department that they is a sample which need some attention in the physical
      department. An officer from chemical department collects the sample and checks in
      LIMS what kind of chemical test is supposed to be performed on this particular sample.
   b. Chemical Homogenization: The sample is then chemically homogenized. This activity
      prepares the sample particles to be in ready for chemical tests (its particles should be
      consistently distributed per cubic millimeter).
   c. Spectra ICP Test
                                           - 11 -
d. Chrome Analysis
  e. Preliminary results: The findings of the two tests are recorded as preliminary results.
  f. Matching: The results are matched with standard. If they are out of limit of the
     standard, they redo the test. If they are within the limit, they are then reported to
     Cement Investigation Department.

4. Reporting: The Cement Investigation Department takes the results that are within the
   limits and published them to the server so that are accessible by client.

Therefore, we can deduce that the delivery time will be affected mainly by the availability of
staff to do the tests and record the tests in time. Before the economic slowdown and before
losing one of their big clients, Maxit, the two departments were so much constrained to
deliver results on time because they were busy attending to other samples.

For Cement Investigation to report the results, all the required tests should be done and
recorded in LIMS. If the physical department is still busy with other samples, the chemical
department would have finished performing the required analyses on this sample and only
waiting for the chemical department to do their part or vice versa. Given the capacity of the
work last year, the two departments were understaffed to cope to the pressure and deliver in
time. In this period of recession and having lost one major client, they can cope and deliver
on time. The chemical department is considered overstaffed and will probably be a victim of
the impending job cuts in CRAB.


To explore delivery time further, let us look at a set of activities that are undertaken in
Physical Department to determine the strength of a sample of cement.

Determination of strength: 1 day strength (Refer to Annex 1.1)

a) Receiving sample
   - Sample sent from Cementa AB is received in the Physical Department of Cementa
     Research AB
b) Homogenization
   - Sample is homogenized. It is taken to another room and put on a homogenizer (a
     machine where the sample is tied with a belt and rotates up and down).
     Homogenization helps to the sample particles to be consistent. This takes
     approximately 30 minutes.
c) Registering sample on paper
   - The sample after being returned to Physical Department is registered on a sheet of
     paper
d) Registering sample in computer
   - Then sample information is recorded in the computer
e) Picking up sample from container
   - Some of the sample is picked up from the container
f) Weighing sample
   - It is placed on a weight to until it reaches a maximum of 1.2 kg
g) Picking up packet of sand
   - A packet of sand weighing 1 kg is taken from a box
h) Mixing up sample with sand
   - 1.2kg of the sample is mixed with 1kg of the sand and some water in a ‘mixing
       machine’. This takes approximately 30 minutes
i) Putting mixture in a ‘molder’
                                        - 12 -
- The 2.2kg mixture is put in a ‘molder’ with two spaces
      j)   Putting mixture in ‘setting machine’
           - The ‘molder’ is put in a ‘setting machine’ to eliminate any air spaces in the mixture
      k)   Putting bricks in ‘moisture chamber’
           - The set mixture forms two bricks in the ‘molder’ which is place in a ‘moisture
             chamber’ for 24 hours.
      l)   Removing bricks
           - After 24 hours, the bricks is removed from the ‘moisture chamber’ and from the
             ‘molder’
      m)   Crushing bricks
           - Both bricks are crushed by a ‘crushing machine’
      n)   Recording results on paper
           - The force used to crush them is what the machine reads as the strength of the brick. The
             reading on the machine is recorded on paper
      o)   Recording results in computer
           - The reading on paper is recorded into the computer
      p)   Results at CID
           - When the results are entered into the computer, Cement Investigation Department gets
             them immediately since they are on a network of computers.
      q)   Communicating results to customer
           - Cement Investigation Department publishes them on the server for the client to be able
             to access them

      From the above progression of activities, it can be seen that there are several factors that can
      affect delivery time. These are:

      a.   Ownership of process
           - Previously, the processes were mapped. This could affect the department in that it may
             not be clear who should do what and work may lie waiting without staff taking the
             responsibility, thus, causing unnecessary delays in delivery time (delivering results to
             customer).
      b.   Number of available machines
           - There is only one homogenizer, one ‘mixing machine’, one ‘setting machine’, one
             scale. Even though they have technicians to repair them when they breakdown,
             machine downtime can affect delivery time. If they have a high capacity, they cannot
             do more than one sample at a time, like mixing two sets of samples at the same time,
             they have to wait for over 30 minutes.
      c.   Number of staff
           - The number of staff in the Physical Department on paper is six but, physically, they are
             only two. In times of high capacity, they cannot cope and even though they are helped
             by staff from Chemical Department, both departments are strained of staff during peak
             periods resulting in extended delivery times. In an event that these two people are
             simultaneously absent and the trained staff in the Chemical Department who helps then
             is on vacation, the work in this department would grind to a halt.


4.5   Other Information

      4.5.1        Management Processes


                                               - 13 -
The company has five departments namely; Chemical, Physical, Cement
        Investigation, Concrete Pre-mix and Software and is headed by a Managing
        Director. Currently, they have 339 projects in which all the 43 members of staff
        are involved. Dispatch testing running is one of the ongoing projects which can
        just be termed as process. The chemical department has twelve people while the
        physical department has six but from the analysis, six seems to the figure on the
        organizational chart while the reality is that they are only two.

4.5.2   Support Processes

        The two departments are supported by the technical and by finance and
        administration staff. The goals and main decisions for these departments are from
        management. They are also assisted in reporting to clients by the Cement
        Investigation department.




                                    - 14 -
5.0   Proposal
      From this study, we can make the following recommendations or proposals for improvement
      in the Physical Department and even the Chemical Department.

      1.   It is necessary to map all or most of the important processes, activities and tasks of each
           test that is carried out in the two departments. This would eliminate the waiting or delay
           points and establish process ownership.
      2.   Train more people in Chemical Department to be able to assist the Physical Department
           in times of pressure and times of emergency.




                                               - 15 -
6.0   Reflections

      The acquisition of theory is the first step in the learning process. If the process ends here,
      then the leaning process is not complete. Applying the theory learned is a fundamental part of
      the learning because this where the assumptions are questioned and knowledge grounded in
      one’s mind. The application of the theories of process management and six sigma in real life
      situation were a reality check to the learning process and a reminder that knowledge once
      acquired have to be adapted to the situations being faced. It cannot be used raw.

      However, time was a great limitation factor in this study. Only two visits were made to the
      factory. All of them on Fridays, one in the afternoon where it was not possible to observing
      the processes happening since some of the staff had already left. It was a great disadvantage
      because, being the first time, a lot of knowledge could have been acquired seeing the actors
      of the processes in play. Therefore, the knowledge acquired was like scattered pieces of a jiq
      saw puzzle. The second visit helped to put these pieces to form a clearer picture. But if there
      was more time accorded to this project, more knowledge and application would have
      resulted.




                                              - 16 -
7.0   References (both written and verbal)

1.    http://www.cementaresearch.se (09-02-2009)
2.    Bergman, B. & Klefjö, B. (2007) Quality from customer needs to customer satisfaction,
      Studentlitteratur, Lund
3.    Bergman, B. & Klefjö, B. (2007) Quality from customer needs to customer satisfaction,
      Studentlitteratur, Lund
4.    European Standards of Cement, EN 197-1:2000 (June 200)
5.    European Standards of Cement, EN 197-1:2000 (June 200)
6.    Patrick Thalin, presentation at Cementa Research on 13-02-2009 and discussions on 06-03-
      2009
7.    Patrick Thalin, presentation at Cementa Research on 13-02-2009 and discussions on 06-03-
      2009
8.    Ann-Kristin Askegren at Cementa Research on 13-02-2009
9.    Bergman, B. & Klefjö, B. (2007) Quality from customer needs to customer satisfaction,
      Studentlitteratur, Lund




                                            - 17 -
Sample
 INPUT                                                                            Testing                                                             Reporting
                       Registration

                                                                                                                                                   Getting Results
                      Homogenization                                              Decision                                                             LIMS
                                                                                  For Test
                                                                                                       Chemical
                       Mark samples                       Physical
                                                          Testing                                       Testing
                                                                                                                                                   Result recording

                       Check test type                                                              Recieving sample
                                                      Receiving sample
                         required                                                                                                                    Reporting to
                                                                                                                                                      customer
                       Record sample                        Testing                                      Chemical
                       details on sheet                                                                Homogenization
                                                                                                                                                       OUTPUT

                     Record sample on                 Results recording                            Spectra ICP testing
                        computer                          on chart

                        Sample bags                    Results recording                             Chrome analysis
                          tagging                        in computer

                                                                                                     Results comparison
                    Filling sample bags                                                                with standards


                                                                                              No                             Yes
                                                                                                           Reporting
                       Putting in box                                                                      Decision
                                                                                          Out of                             Within
                                                                                          limit                              limit



Annex 1 - Process Diagram (adapted from the descriptions given at CRAB and from the knowledge gained from APM lectures at Gotland University in February and March 2009)
Annex 1.1 – Sub Process Diagram (adapted from the descriptions given at CRAB and from the knowledge gained from APM lectures at Gotland University in February and March 2009)
(W indicates potential waiting /delay points)

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Cementa Ab Applied Process Management Group Iv Report Process Blue Printing

  • 1. -0-
  • 2. Table of Contents Executive Summary .......................................................................................................................... 2 1.0 Background ................................................................................................................ 3 2.0 Work Methodology .................................................................................................... 4 2.1 Methodology Used ............................................................................................................ 4 2.2 Cementa Research AB ....................................................................................................... 4 2.2.1 The Company ............................................................................................................. 4 2.2.2 Services Offered ......................................................................................................... 4 2.2.2.1 Product Control................................................................................................... 4 2.2.2.2 Product Development ......................................................................................... 4 2.2.2.3 Equipment and Machinery .................................................................................. 4 2.2.2.4 Process Development.......................................................................................... 4 2.2.2.5 Quality Control and Environmental Issues ......................................................... 5 3.0 Theory Used............................................................................................................... 6 3.1 Process ............................................................................................................................... 6 3.2 Process Classifications ....................................................................................................... 6 3.3 Process charting ................................................................................................................. 7 3.4 Flow chart .......................................................................................................................... 7 3.5 Six Sigma ........................................................................................................................... 8 4.0 Results ....................................................................................................................... 9 4.1 CEN and EN-197 ............................................................................................................... 9 4.2 Stakeholders ....................................................................................................................... 9 4.3 Process Descriptions .......................................................................................................... 9 4.3.1 Sample Registration ................................................................................................... 9 4.3.2 Testing ...................................................................................................................... 10 4.3.2.1 Physical Testing ................................................................................................ 10 4.3.2.2 Chemical Testing .............................................................................................. 10 4.3.3 Reporting .................................................................................................................. 10 4.4 Measurable Parameters .................................................................................................... 10 4.5 Other Information ............................................................................................................ 13 4.5.1 Management Processes............................................................................................. 13 4.5.2 Support Processes ..................................................................................................... 14 5.0 Proposal ................................................................................................................... 15 6.0 Reflections ............................................................................................................... 16 7.0 References ............................................................................................................... 17 Annex 1 .......................................................................................................................................... 18 Annex 1.1 ....................................................................................................................................... 19 -1-
  • 3. Executive Summary Process management seems more of an engineering tool to only be used in a manufacturing industry but it can be used effectively in management to map a process and discover problem areas (if any) or be used as a stimulus to improve the system. MIM students utilized the tool in dispatch testing to describe processes and analyze measurable parameters in the process. After thorough analysis of activities in two departments of Cementa Research AB (CRAB), chemical and physical departments, they discovered a few some areas which can be improved relative to delivery time. However, the project was undertaken at a very tricky period. Two events had overtaken CRAB that have and will continue to have tremendous impact on their operations. One of them is the loss of their major client, Maxit and the other one is the global economic recession. Thus, the workload has been reduced and the pressure has disappeared. -2-
  • 4. 1.0 Background MIM students studying Applied Process Management (APM) at Gotland University were compulsorily commissioned to undertake a group project running simultaneously alongside APM lectures. The overall aim was to marry theory with practical, divorce of which would produce half- baked students out of this academic oven. The specific area of focus was selected by the course instructor and the underlying tasks thereof. Different groups were allocated to different organizations but all of them were charged with studying a given process in the organization, preparing an overall process chart and proposing any improvements that can be made. Group IV was appointed to undertake a process charting at Cementa Research AB. Group meetings and company visits were made. Group members’ and team leaders’ knowledge, creativity, experiences and tireless efforts in this project are conferred herein as a project report. -3-
  • 5. 2.0 Work Methodology Here we describe the methodology that was used in undertaking the whole exercise. 2.1 Methodology Used The project team (leaders and crew) held several meetings to plan for the project. The crew had to revisit theory on process charting and dig out some information from the firm’s website prior to visiting CRAB on 13th February 2009. During the visit, the team was shown the whole process and then it was treated to a presentation about the process and the firm. Another visit was taken on 7th March 2009, where the project crew gained in depth knowledge about the chemical and physical analyses that are conducted. Consolidation concomitant to the visits and several team meetings have given birth to this report. 2.2 Cementa Research AB1 2.2.1 The Company This is a research company owned by Cementa AB which operates in Sweden under Cementa Heidelberg Cement Group. It employs 45 people who work in five production groups namely; chemical analyses, physical testing, cement investigation, cement premix and software development. These production groups work in coordination with the MD, Secretary and a Technical Department. Cementa Research AB (CRAB) was accredited as a testing laboratory by Swedac (Swedish Board for Technical Accreditation) for almost 150 testing methods. The company is situated in Slite where it has a laboratory which is well equipped with modern facilities and equipment which is used to undertake consultancy services, analyses and to bring new knowledge into Heidelberg Cement. 2.2.2 Services Offered Though its main activities are in mineral based materials, it goes over and above this. It works with fuels, drinking water and waste water; environmental analyses, measurements, environmental audits and development of environment management system of a company. The Slite laboratory is equipped to undertake organic and inorganic chemistry functions as well as physical testing. Its competence revolves around microbiology, theology and indoor environment. In mineral based building materials it has four main activities namely; product control, product development, quality and environmental techniques and improvements in the processing industry. 2.2.2.1 Product Control In product control area, they use different methods or standards to control the quality of cement and concrete. -4-
  • 6. 2.2.2.2 Product Development Product development ensures quality of cement and concrete with respect to different dimensions like durability of building materials, the mixing quantity of different materials etc. Product development contributes in continuous development towards better and more specialized products and it enhances the competitive capability of the cement plant and helps in increasing its demand as compared to its substitutes. 2.2.2.3 Quality Control and Environmental Issues In quality and environment, Cementa AB runs different quality projects in the field of cement and concrete production. It helps its customers in building quality systems for certification and it also performs some type of quality audits. 2.2.2.4 Process Development Leveraging on experienced employees, in process development, it performs different comprehensive consultancies. It helps in improving products or productivity to make the production more economical. 2.2.2.5 Equipment and Machinery Cementa Research AB uses a lot of equipment in the following categories; chemical analyses, particle size distribution and surface area measurement, microstructure, cement testing equipment, concrete testing equipment, coal testing, air and gas analyses, climate equipment and computer system. It also produces quality handbooks, quality documents which are adjusted time and again to guide and help them in offering their services to customers. -5-
  • 7. 3.0 Theory Used The theory on which the project was based is discussed below. 3.1 Process Process originate from the ‘processus’ and ‘procedere’ which are all Latin words which mean ‘advancement’ or ‘move ahead’. 2 The concept of process can be applied in various aspects or fields but in this project, the concept is narrowed to management. Hence, it is defined as a set of activities with a specified beginning and end, which, using the resources of an organization, repeatedly adds value to a measurable object from a supplier to a predetermined measurable result to a customer.3 Interface Supplier Process Customer/Stakeholder Input Output Value-adding Resources Figure 3.1.1 Process Diagram (From Bergman, B. & Klefjö, B. 2007) 3.2 Process Classifications Processes can be distinguished by their aims. Using this classification, three types of processes are realized, main, support and management processes. Main processes are core processes, whose tasks are geared towards satisfying the external customers’ needs, creating value for them and improving the products delivered by the organization. Support processes are these are feeder processes because they feed resources into the main process. Management processes are determinant processes in that they set targets, devise strategies and work out improvements in the other processes in the organization. In a process there are both internal and external customers. The internal customers are the recipients of the output of the other departments which use them as primary inputs in their activities while external customers are those that are outside the organization and they are usually the ones that matter a lot because all the departments and -6-
  • 8. the main process using the organizational resources like information and energy work to serve and satisfy their needs.3 3.3 Process charting Process charting is a graphical method of showing an array of steps through which input is converted to output. A process chart defines ownership, customer and boundaries. It helps in finding control points, in this way it easy to establish measurements and show results. Different process models can be used by any organization as a way of identifying performance measurements and examining the process in detail to identify areas of possible improvements. Proposed organizational system model, proposed basic process model, and generic process model are commonly used for process measurements. Main process Activity A Activity B Activity C Activity D B1 B2 B3 B3a B3b B3c Figure 3.3.1 Process Diagram (From Bergman, B. & Klefjö, B. 2007) 3.4 Flow chart A flow chart is a series of activities that are connected to one another sequentially determined by appropriate decisions that are required to proceed to them. It can be used to find the process improvements in detail. Flow charts are useful diagrams showing the steps of a process clearly and how processes work. It is easy to understand the whole process step-by- step. The organization can find what really happens next in the process; what the next step is; what errors and wastes occur and where the process should be improved from start to the end. Excellent flow charts show us every important detail of main process, sub process, activities, and work tasks clearly. Y Y Start If Activity If Activity Stop N Y Y No Activity Activity Activity N Stop -7-
  • 9. Figure 3.4.1 Flow chart (Adapted from the Applied Process Management lecture of 20-01-2009 at Gotland University) 3.5 Six Sigma The essence of survival of a firm lie in the satisfaction and retention of customers. Customer satisfaction is the duty of the overall company not just of the marketing department. The marketing department can be the overall overseer of meeting a standards of customer satisfaction. Customer seek consistency. They are loyal to a firm that offer a consistent product or service. Six sigma is one of the tools that can be used to measure variations in various processes that lie in the path of adding value to an input all the way to delivering an output into the hands of a customer. Variations in processes are definitely affect the quality of the product and will eventually be passed on to the customer. Six Sigma was originally developed by Motorola in the 1980s as a quality improvement tool. Basically it was used to reduce the number of defects and unwanted variations in the organizational process. Six Sigma provides a systematic methodology to process improvement. When companies are using this the Six Sigma approach to quality improvement, “process flow” and “standard” are the most important concepts. They aim to achieve the possible and necessary improvements. The steps that are followed in this approach are abridged to DMAIC which stands for Define Measure Analyse Improve and Control. DMAIC can be easily understood in a numerical layout as below: 9 - Define high-level project goals, and the current process - Measure key aspects of the current process and collect relevant data. - Analyze the data to verify cause-and-effect relationships. Determine what the relationships are, and attempt to ensure that all factors have been considered. - Improve or optimize the process based upon data analysis using techniques like Design of experiments. - Control to ensure that any deviations from target are corrected before they result in defects. Set up pilot runs to establish process capability, move on to production, set up control mechanisms and continuously monitor the process.” -8-
  • 10. 4.0 Results The findings of the project follow hereinafter. 4.1 CEN and EN-197 Cement is a hydraulic binder. It is finely ground inorganic material that forms a paste when mixed with water. The paste sets and hardens by means of hydration reactions and processes but after hardening, it retains its strength and stability even under water. 1 Sweden is a member of CEN (Comité Européen de Normalisation) which European Committee for Standardization. CEN members are bound to comply to EN 197-1 which is the European Standard about composition, specifications and conformity criteria for common cements. 4 Cement has to conform to EN 197-1 in mechanical, physical, chemical and durability requirements. Mechanical requirements entail standard and early strength while physical requirements focus on initial setting time and soundness. Chemical requirements revolve around composition of the in terms of elements like hydrochloric acid, sodium carbonate, sulfate and chloride while durability looks at the cements ability in terms of frost resistance, chemical resistance and protection of reinforcement.5 Therefore, to check this conformity, cement has to be tested, hence the existence of Cementa Research AB. 4.2 Stakeholders The stakeholders or clients that benefit from this process or organisation are Cementa Slite Plant and Cementa Marketing Department. The process is called dispatch testing meaning that they get a sample from the lot that is going to be dispatched and test it. Apart from controlling quality of final product, (thus physical and chemical properties) and ensuring SPC, this process is also undertaken to maintain product database for Cementa and Cementa customers.6 The process for checking conformity has never been mapped so mapping process descriptions and showing process ownership will be an improvement and so will be shortening delivery time so that it is shorter or good enough for the customer. 7 4.3 Process Descriptions8 4.3.1 Sample Registration Sample registration sometimes starts with homogenization or ends with homogenization. It just depends on the officer; he can homogenize it first or do the other steps first and lastly homogenize it. Depending on what choice he has made, he goes to mark the container of the sample and then check what test is required from a check sheet. Previously, they did not have to check the kind of test needed because for every sample, they were doing the full test, but now, due to an economic slump, they have to choose which sample has to go through a full test or a reduced test or just a physical test. He records the sample details into a table and record more details about the sample in the computer. After this, an air tight, sealable small storage bag is marked and some amount of the sample is put -9-
  • 11. in the bag and stored in a wooden box ready for collection by the chemical department. 4.3.2 Testing 4.3.2.1 Physical Testing Physical testing is performed in the physical department. They take part of the sample from the dispatched container and mix it with either water or sand or just use it the way it is. After the physical test, they record the results on a sheet of paper and then transfer them to the computer. 4.3.2.2 Chemical Testing When the sample details are recorded in the computer, it registers in the chemistry department computers that there is a new sample which needs to be analyzed. They get the sample from the physical department and check in the computer what kind of test (thus, either full or reduced) is supposed to be performed on this particular sample. They later do a chemical homogenization as a way of preparing the sample and then they do a Spectra ICP Test, and then Chrome analyses. After these, they get the preliminary results and match those results with the standards. If the results are out of limit of the standards, then, they redo the test. Otherwise, they enter the results in the computer using LIMS (Laboratory Information Systems). 4.3.3 Reporting When the results are entered into the LIMS, they are checked by the Cement Investigation Department. If they are within the required parameters, they are released and published to the server so that the client can access them online. (For a complete illustration of the above processes, please refer to Annex 1) 4.4 Measurable Parameters The only measurable parameter which can be used as a basis for improvement is delivery time, thus, the time taken from receiving the sample to releasing the report to the client. The chemical and physical department activities were followed closely to determine the delivery time. To start with, there is delivery time is set by the client. That is to say, the client put a reasonable demand as to when they want the results. To follow this parameter correctly and to analyze the activities deeply, Cementa AB Marketing department will be used as the only client. Cementa AB can bring a sample that has to be analyzed and be reported on and it specifies a delivery time. Basically, this is what will be involved to reach that end: 1. Sample Registration a. The sample container is marked with the sample number (continuation of numbers derived from a LIMS) - 10 -
  • 12. b. The sample is taken for homogenization: Here the container is put on a machine which rotates together with the sample container and continually shaking the contents inside for 30 minutes. c. A sheet of paper is checked to see what kind of test is supposed to be done on this sample and then the sample details are recorded on the same sheet d. The sample details are recorded into LIMS e. Activities b, c and d can take approximately five minutes, thus, thirty-five minutes together with activity b. However, the reader should note that the sample is not put in a homogenizer and the officer stands there for thirty minutes waiting for it. He continues with other tasks. f. A sealable, air-tight A6 plastic bag is marked with the sample details and two tablespoonfuls of the sample are placed into this bag and put into a box ready to be collected by the physical department. 2. Physical Testing Several physical tests can be performed on this sample but the priority ones include a. Fann: Here a part of the sample is mixed with water to make slurry and the slurry is tested for its thickness using a Viscometer. The resistance recorded on this machine is the thickness. This figure is recorded immediately on a sheet of paper to be transferred later to the computer. This takes approximately one and a half hours. b. Vicat vatten (setting time): Here, part of the sample is mixed with water to form slurry and then put in water and a needle from a gadget comes and pierces into this slurry at intervals set by the officer. It continues to jab into this slurry until it cannot sink into it more than 22 mm. This may take from 20 to 180 minutes. c. Laser: Here less that a teaspoonful of the sample is taken and spread on a microscope like machine which calculates the size of the particles of the cement. This takes less than 30 minutes. d. Blaine is a different form of a laser analysis e. Determination of strength: Here, part of the sample is mixed with sand in a machine for 30 minutes. From the ‘mixer’ it is spread into a ‘molder’ which is placed into a machine which lifts it every 2.5 seconds. After fifteen minutes, it is removed and the brick(s) formed are placed in a moist chamber for one day and removed the following day. After removing the brick, depending on the type of analysis, it is subjected to further tests. For example, if it is 1 day strength, it is immediately taken to a machine that crushes it. If it is 2 days strength, then it is placed in water for two days and after that is crushed. If is a 28 days strength, it is placed in water for 28 days and then removed and crushed. The results for each test are recorded on a paper first then transferred into LIMS. Thus, when a test is completed, the results can go into LIMS immediately, subject to how busy the officer is. The department is manned by two officers and occasional assistance from one staff from chemical department. 3. Chemical Testing a. Collection of sample: When the sample details are recorded n LIMS, it registers in the chemical department that they is a sample which need some attention in the physical department. An officer from chemical department collects the sample and checks in LIMS what kind of chemical test is supposed to be performed on this particular sample. b. Chemical Homogenization: The sample is then chemically homogenized. This activity prepares the sample particles to be in ready for chemical tests (its particles should be consistently distributed per cubic millimeter). c. Spectra ICP Test - 11 -
  • 13. d. Chrome Analysis e. Preliminary results: The findings of the two tests are recorded as preliminary results. f. Matching: The results are matched with standard. If they are out of limit of the standard, they redo the test. If they are within the limit, they are then reported to Cement Investigation Department. 4. Reporting: The Cement Investigation Department takes the results that are within the limits and published them to the server so that are accessible by client. Therefore, we can deduce that the delivery time will be affected mainly by the availability of staff to do the tests and record the tests in time. Before the economic slowdown and before losing one of their big clients, Maxit, the two departments were so much constrained to deliver results on time because they were busy attending to other samples. For Cement Investigation to report the results, all the required tests should be done and recorded in LIMS. If the physical department is still busy with other samples, the chemical department would have finished performing the required analyses on this sample and only waiting for the chemical department to do their part or vice versa. Given the capacity of the work last year, the two departments were understaffed to cope to the pressure and deliver in time. In this period of recession and having lost one major client, they can cope and deliver on time. The chemical department is considered overstaffed and will probably be a victim of the impending job cuts in CRAB. To explore delivery time further, let us look at a set of activities that are undertaken in Physical Department to determine the strength of a sample of cement. Determination of strength: 1 day strength (Refer to Annex 1.1) a) Receiving sample - Sample sent from Cementa AB is received in the Physical Department of Cementa Research AB b) Homogenization - Sample is homogenized. It is taken to another room and put on a homogenizer (a machine where the sample is tied with a belt and rotates up and down). Homogenization helps to the sample particles to be consistent. This takes approximately 30 minutes. c) Registering sample on paper - The sample after being returned to Physical Department is registered on a sheet of paper d) Registering sample in computer - Then sample information is recorded in the computer e) Picking up sample from container - Some of the sample is picked up from the container f) Weighing sample - It is placed on a weight to until it reaches a maximum of 1.2 kg g) Picking up packet of sand - A packet of sand weighing 1 kg is taken from a box h) Mixing up sample with sand - 1.2kg of the sample is mixed with 1kg of the sand and some water in a ‘mixing machine’. This takes approximately 30 minutes i) Putting mixture in a ‘molder’ - 12 -
  • 14. - The 2.2kg mixture is put in a ‘molder’ with two spaces j) Putting mixture in ‘setting machine’ - The ‘molder’ is put in a ‘setting machine’ to eliminate any air spaces in the mixture k) Putting bricks in ‘moisture chamber’ - The set mixture forms two bricks in the ‘molder’ which is place in a ‘moisture chamber’ for 24 hours. l) Removing bricks - After 24 hours, the bricks is removed from the ‘moisture chamber’ and from the ‘molder’ m) Crushing bricks - Both bricks are crushed by a ‘crushing machine’ n) Recording results on paper - The force used to crush them is what the machine reads as the strength of the brick. The reading on the machine is recorded on paper o) Recording results in computer - The reading on paper is recorded into the computer p) Results at CID - When the results are entered into the computer, Cement Investigation Department gets them immediately since they are on a network of computers. q) Communicating results to customer - Cement Investigation Department publishes them on the server for the client to be able to access them From the above progression of activities, it can be seen that there are several factors that can affect delivery time. These are: a. Ownership of process - Previously, the processes were mapped. This could affect the department in that it may not be clear who should do what and work may lie waiting without staff taking the responsibility, thus, causing unnecessary delays in delivery time (delivering results to customer). b. Number of available machines - There is only one homogenizer, one ‘mixing machine’, one ‘setting machine’, one scale. Even though they have technicians to repair them when they breakdown, machine downtime can affect delivery time. If they have a high capacity, they cannot do more than one sample at a time, like mixing two sets of samples at the same time, they have to wait for over 30 minutes. c. Number of staff - The number of staff in the Physical Department on paper is six but, physically, they are only two. In times of high capacity, they cannot cope and even though they are helped by staff from Chemical Department, both departments are strained of staff during peak periods resulting in extended delivery times. In an event that these two people are simultaneously absent and the trained staff in the Chemical Department who helps then is on vacation, the work in this department would grind to a halt. 4.5 Other Information 4.5.1 Management Processes - 13 -
  • 15. The company has five departments namely; Chemical, Physical, Cement Investigation, Concrete Pre-mix and Software and is headed by a Managing Director. Currently, they have 339 projects in which all the 43 members of staff are involved. Dispatch testing running is one of the ongoing projects which can just be termed as process. The chemical department has twelve people while the physical department has six but from the analysis, six seems to the figure on the organizational chart while the reality is that they are only two. 4.5.2 Support Processes The two departments are supported by the technical and by finance and administration staff. The goals and main decisions for these departments are from management. They are also assisted in reporting to clients by the Cement Investigation department. - 14 -
  • 16. 5.0 Proposal From this study, we can make the following recommendations or proposals for improvement in the Physical Department and even the Chemical Department. 1. It is necessary to map all or most of the important processes, activities and tasks of each test that is carried out in the two departments. This would eliminate the waiting or delay points and establish process ownership. 2. Train more people in Chemical Department to be able to assist the Physical Department in times of pressure and times of emergency. - 15 -
  • 17. 6.0 Reflections The acquisition of theory is the first step in the learning process. If the process ends here, then the leaning process is not complete. Applying the theory learned is a fundamental part of the learning because this where the assumptions are questioned and knowledge grounded in one’s mind. The application of the theories of process management and six sigma in real life situation were a reality check to the learning process and a reminder that knowledge once acquired have to be adapted to the situations being faced. It cannot be used raw. However, time was a great limitation factor in this study. Only two visits were made to the factory. All of them on Fridays, one in the afternoon where it was not possible to observing the processes happening since some of the staff had already left. It was a great disadvantage because, being the first time, a lot of knowledge could have been acquired seeing the actors of the processes in play. Therefore, the knowledge acquired was like scattered pieces of a jiq saw puzzle. The second visit helped to put these pieces to form a clearer picture. But if there was more time accorded to this project, more knowledge and application would have resulted. - 16 -
  • 18. 7.0 References (both written and verbal) 1. http://www.cementaresearch.se (09-02-2009) 2. Bergman, B. & Klefjö, B. (2007) Quality from customer needs to customer satisfaction, Studentlitteratur, Lund 3. Bergman, B. & Klefjö, B. (2007) Quality from customer needs to customer satisfaction, Studentlitteratur, Lund 4. European Standards of Cement, EN 197-1:2000 (June 200) 5. European Standards of Cement, EN 197-1:2000 (June 200) 6. Patrick Thalin, presentation at Cementa Research on 13-02-2009 and discussions on 06-03- 2009 7. Patrick Thalin, presentation at Cementa Research on 13-02-2009 and discussions on 06-03- 2009 8. Ann-Kristin Askegren at Cementa Research on 13-02-2009 9. Bergman, B. & Klefjö, B. (2007) Quality from customer needs to customer satisfaction, Studentlitteratur, Lund - 17 -
  • 19. Sample INPUT Testing Reporting Registration Getting Results Homogenization Decision LIMS For Test Chemical Mark samples Physical Testing Testing Result recording Check test type Recieving sample Receiving sample required Reporting to customer Record sample Testing Chemical details on sheet Homogenization OUTPUT Record sample on Results recording Spectra ICP testing computer on chart Sample bags Results recording Chrome analysis tagging in computer Results comparison Filling sample bags with standards No Yes Reporting Putting in box Decision Out of Within limit limit Annex 1 - Process Diagram (adapted from the descriptions given at CRAB and from the knowledge gained from APM lectures at Gotland University in February and March 2009)
  • 20. Annex 1.1 – Sub Process Diagram (adapted from the descriptions given at CRAB and from the knowledge gained from APM lectures at Gotland University in February and March 2009) (W indicates potential waiting /delay points)