Suggested Contents of a Process Design Guideline Manual

01. Cover Page indicating Issue No., Date, Review and Approval
02. Contents Sheet
03. Revision Record
04. Introduction to the Manual
05. Introduction to the Product
06. Past problems in manufacturing and at customer-end in same or similar parts
07. TGR / TGW Reports of previous developments, learning’s from the past
08. Guidelines for fixing process benchmarks and collecting benchmark data
09. Guidelines for preparing Process Design Input Sheet
10. Manufacturing strategies and technological options
11. Guidelines for preparing Stage Drawings (if applicable)
12. Guidelines for preparing Process Flow Diagram Preparation
13. Selection of equipment for each process: criteria to be adopted.
14. Part holding requirements for each process and inputs for Fixture Design
15. Selection of Cutting / Other Tools for carrying out each process step
16. Selection, use and life control of coolants, cutting oils, lubricants, consumables,
etc.
17. Important process parameters / variables for each product characteristic
18. Guidelines for preparing and using a Characteristic Matrix
19. Guidelines for Process FMEA (or linkage to Work Instruction)
20. Guidelines for preparing Pre-launch Control Plan (or linkage to Work Instruction)
21. Guidelines for preparing Set-up Instructions and Work Instructions
22. Typical rework operations that could arise in each process.
23. Guidelines for preparing Rework Instructions
24. Part washing and contamination control requirements
25. Error-proofing requirements (Prevention-type and Detection-type)
26. Guidelines for defining Process Approval Acceptance Criteria for each stage of trial
run
27. Critical machine parameters that need be verified on an on-going basis to assure
product quality (input to Plant Maintenance).
28. Guidelines for designing material storage and transportation devices
29. Special product characteristics and requirements for (a) SPC, (b) Process
Performance / Process Capability and (c) Process Stability Monitoring.
30. Guidelines for selection of process control instruments
31. Guidelines for selection of product quality checking instruments / gauges
32. Requirements for MSA for new measurement systems – types of studies to be
conducted, acceptance criteria.
33. Approved Tier-2 suppliers to which processes could be outsourced
34. Receiving inspection requirements for out-sourced processes
35. Work Environment requirements for defect-free manufacturing and inspection
36. Operator skill and competence requirements
37. Checklists for (a) Set-up Verification, (b) In-process Inspection, (c) Final Inspection
38. Selection of Sampling Plans for inspection
39. Guidelines for Cell Design and Layout
40. Safety and Environmental Protection requirements
41. Change control and customer notification requirements
42. Typical Reports (routine, periodic) to be submitted to customer
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