CTR, an aerospace part manufacturer, was flow-charted. The company was broken down into 7 main processes from the "Quote to PO process" to the "Shipping to Invoice process". Instead of writing a 300 page manual, the above was created. Keep in mind that the original is a hyper-linked PDF for ease of workflow navigation.

1. By Location By Job Function By Processes

2. WO Traveller to Floor Traveller Close Out
Quote to PO Process PO to Traveller Floor to Final Inspection
Kitting Traveller to Floor Shipping to Invoice-Stock

3. CTR, Inc.
“Quote to PO” Procedure
Doc Control produces:
Start creating and 1.Part Labels Double Check:
Part List received at Revision Place labels and kit-
Doc Control No breaking down Part 2. Manufactured Kit-List kit-lists verified by Problems? No Inform PM
Document Control Change? lists into the M Drive
CCed on List 3. Purchased Kit-List other Doc Control
email
Document Control
Yes
Yes
M Drive
Begin Revision Change Talk to previous
Internal or
Procedure personnel that held
Internal external?
documentation
Part List Kit Lists Tab & Labels Tab
Doc Control
CCed on
External
email
Contact Customer
for clarification
M Drive
Senior Program Manager (Pricing)
M Drive M Drive
Inform Assistant
Review Kit Lists and
PM informed Problems? No Quoter about
Tabs
Info Received by Give Part List to Verified Kit Lists Final Quote
Review Part List Problems? No Review part prices to Final Quote Price
email Document Control PM reviews Enter prices into Price
ensure profit margin. reviewed and then
Yes formulated Kit-List formulated Kit-List produced by
5 Methods emailed to Customer
formulas
Yes? Talk to previous
Internal or
personnel that held
external?
documentation Internal
PM begins
Contact Customer External renegotiation w/
for clarification customer
Contact Customer Quote Tab
for clarification
Assistant Quoter Apply pricing
enters M drive and Review Kit Lists and formulas to Kit-List Info PM of formula
M Drive Problems?
opens verified Kit Tabs w/ Quote Sheet inputting Kit-List
Lists
Assistant Quoter
Yes
Part List
Talk to previous
Internal or
personnel that held
external?
documentation Internal
Quote Tab
External
Contact Customer
for clarification
Stakeholders (Customer)
“Quote to PO” Procedure
Customer received Quote PO to Traveller
Contact PM for Yes
Buyer
Quote Accepted? Process Begins
Quote to PO Process Ask for Quote by Customer gives Customer renegotiation
Begins email w/ Part List clarification contacted.
No
Document Control
ADCN: Advanced Document Change Notice
Email part list with Customer gives Customer
Quote to PO Process DCN: Document Change Notice Customer gives Customer
either an ADCN or clarification contacted.
Begins
DCN clarification contacted.
Or Or
Engineering
Customer gives Customer
clarification contacted.

4. CTR, Inc.
“PO to Traveller/s” Procedure
AKA Direct Shipping
VP CCed on
email Begin Risk
Give PO and VP receives PO & Pass Risk Risk Assessment Is this a “Pull to “Direct Shipping” Procedures
Begin Review Print PO and Assessment Yes Yes Take to the Floor
Receive supporting Acknowledgment Assessment? Signed Stock” PO? (Pull from Stock)
Process. supporting Process
Customer’s PO documents to Doc
(PO Revision check) documents
Control
No
Delivery Date Criteria
VP
No
Give PO, Risk Assessment,
and Acknowledgment to
Supporting Document: Doc Control
Inform customer of
Email of Quote Agreement situation
No Receive PO, Risk Use copy to create Traveller
Review documents and
Assessment, and Make 1 Copy Original or copy? Copy WO Traveller and Creation Traveller to Floor
apply corrections
Doc Control Doc Control Acknowledgment from VP print drawings Process Begins
Begin Give PO &
CCed on receives Is the package Validate VP Revision Does the Revision
Yes No Acknowledgement Acknowledgment to
email PO and supporting complete? Change Decision Change?
Document Control
Process VP
documents. Original
Reason for Check: M Drive
 Verify signature
Yes
 Verify Stamp of Approval Original placed File
 Verify delivery dates Cabinet.
(Open Cabinet)
Begin Revision
Correction
Process
Client PO
M Drive
Stakeholders (Customer)
“PO to Traveller/s” Procedure
Reply
Replied to Quote Client makes Client Receives
PO Created Send PO to CTR
(if any) changes Information
Buyer
PO to Traveller
Process Begins

5. CTR, Inc.
WO Traveller to Floor
Kits Give WO Traveller to Kitting Traveller to
Document Control
(Kitting) PM Floor
What type of
Traveller to Floor
Travellers?
Stock: Build to Forecast
Give WO Traveller to Kitting Traveller to
&
Planning Floor
Details & Assemblies
Reason for Check:
 Multi-Order Consolidation
 Rev Change Likelihood
 Resource Management
 Time to Delivery
 “Floor Flooding”
Estimate Routings
1. General Costs
Planning receives Review all WO 2. Check Routings Machining or
Criteria Check? Pass
WO Traveller Travellers 3. Verify BOM Sheet Metal? Sheet Metal
4. Verify Material
5. Apply Back Date
Planning
Fail
Machining
WO Traveller/s Internal or
Internal
place “On Hold” External?
External
Return to Document
Control
Machine – VP of Manufacturing
Machine Supervisor
Review WO Inprocess Inspection Floor to Machine
Receives WO Issues? No
Traveller/s Complete Processes
Traveller/s
Yes
Planning Approval
Return to Planning
Sheet Metal- VP of Fabrication
Sheet Supervisor
Review WO Inprocess Inspection Floor to Metal Sheet
Receives WO Issues? No
Traveller/s Complete Processes
Traveller/s
Yes
Planning Approval
Return to Planning

6. CTR, Inc.
Kitting To Floor
Build to Stock Process
Consolidates Travellers
in multiples of 10.
M Drive M Drive
Document Control
Kitting Traveller to
Floor Update Inventory items, WO Creation Processes
Doc Control receives Review Modified-
detail drawings, and for Details and Traveller to Floor
Printed BOM Printed BOM
assemblies drawings Assemblies
PM’s Personal Inventory Checklist
Modified-Printed BOM
PO for Outside Manufactured Parts
Quantity X # of Kits Give BOM to Research special items
on Print BOM list Document Control and vendor sources
Senior Program Manager (Pricing)
Yes
Printed BOM Yes
No CTR PO
Scrub and Reconcile Use notes and Begin Purchasing of
PM receives WO Same kit repeat in 90 Consolidated Check Bill of Consolidated Special/new Give PO to VP for
Yes Print BOM list No O/H Inventory? Sure BOM to build Multi-Action review for outside No Outside Manufacturing CTR PO created
Traveller days? Kit Travellers Materials (BOM) Kits? Purchase Parts? Signature
(Build vs OH Inventory) manufacture parts Parts
No Sure
Build to Stock Process Give Traveller to
Inventory Check
Printed BOM Procurment
Panasonic Open PO List Regardless of type (Electronic,
manufacturing, etc)
Build to Stock
Process
Signatures can also be performed by the
Quality Manager
VP or QC Manager
VP
receives PO for VP/QC signs PO Receiving Process
Signature
CTR PO
PO for Electronic and Electric Parts
Job is need before the Give PO to VP
2 weeks.
Purchase Hardware
Criteria CTR PO
Update E2 based Begin Purchasing of
Procurment receives Check Panasonic Perform an Urgency File Purchasing
Urgent? Multi-Action on Inventory Inventory O/H? No Electronic and electric PO created Multi-Action
Traveller Open PO LIst Check Hardware List
Procurement
Results Parts
No Yes
Consolidated Create Purchase Hand Purchase Procurement is
Travellers for the Hardware List to Hardware List to notified and handed
Panasonic Open PO List Month Consolidate Needs Shipping Supervisor the PHL. Pull Inventory from E2 Urgent? No Wait 2 Weeks
Purchase Hardware List
Yes
Release Kitting
Travellers to the
Purchase Hardware List Shipping
Shipping Supervisor Shipping Supervisor Inventory
receives Hardware assigns list to Checking
List shipping personnel Process
Shipping to Invoice/
Stock
Shipping
Purchase Hardware List
Shipping Supervisor Shipping Supervisor
receives ‘Urgent’ assigns Urgent
Request and request to shipping
Traveller personnel