Implementation the PDCA model to processes level

BUSINESS PROCESS MANAGEMENT

BUSINESS PROCESS
PLAN

DO

CHECK

ACT

feedback process
MESUREMENT, ANALYSIS, IMPROVEMENT

SUPPORT PROCESSES
assurance of resources and infrastructure for process

Sequence of Processes

a.
b.
c.
d.

Integrated management processes are organized into four levels:

management processes;
resources assurance processes;
product realization processes / operational control;
measurement, analysis, improvement processes.

Each process implementation comply five stages:

planning stages;
resources ensuring stages;
operating stages;
monitoring and measuring stages;
improving stages.

Two processes are in interaction when the outputs of a phase of the precursor
process constitutes input data for the next step of the process.

Interaction of processes Integrated Management System

Continual improvement of
Integrated Management System

Management
responsibility
CUSTOMERS

Resource
management

CUSTOMERS

Requirements

Measurement,
analysis and
improvement

Input

Satisfaction

Output

Product
realization

PRODUCT
Process 1

Value-adding activities

Information flow

Integrated Management System

Build up IMS
Manual Integrated Management
Control Procedure
General Procedure
Work Procedure/Instruction
Implement in company
Surveillance
third part audit
customer audits
internal audits
Up-to-date Manual Integrated Management
Customers
Owner
Surveyor Bodies

Hierarchy of System Quality Documents

Quality
Manual
Quality Control
Procedures
Quality General
Procedures
Process Spec.& Instructions
Documents & Records
6

Supplier

Input

Company

Processes List
Activities

All Depts.
Self (QA)
QC &NDT

Process

Output

Customer

Quality Manual

CEO

ISO 9001:2000
Draft procedure QMS consolidation

Certificates
Agreements

CEO
Originator Dept.

Audit Programm Internal audit

Audit report
CAR

CEO
Audited Dept.

CAR

All depts.
CEO

Quality Control Quality report

Product Control Complaints

Design & Implement QMS Procedures

Corrective/preventive
Actions

QC &NDT
Audited depts

Reports
Audit reports

Control of Docs&Records Quality reports

Product Control

Specifications
Contract

Product Control

CARs

All depts.
Quality Manager

Quality planning

QITP
QITP revisions

Marketing
Engineering &QC

Claim sheet
Customer CAR

Complains review

Proposals for
corrective actions

Claims Committee
Project Manager

Purchasing

Potential
Supplier List

Suppliers assessment

Audit report

CEO
Purchasing Dept.

Quality Control

Call for witness

inspection

Communication

E-mail, Fax

Surveyor Society

Supplier

Input

Planning
Shop

Traveler

Shop

HT Chart

NDT

NDT defect MAP

Subcontractant Request of
Sub contracting

Process

Inspection

Checking & issuing

official reports

Output
Measurements
confirm on TRV
HTR

Excavation MAP

Inspection part at / from

subcontractant

Inspection
report

HT Technology
TRV

Issuing Request Bill

Planning &PC
Self (QC)

HT Technology
Request Bill

Certificate
Communication with Lab.
type 3.1 ISO

Shop
Self (QC)

Part
Measurements

Control of

Shop
Planing & PC

Call for witness

Presentation part at
final inspection

Engineering
Planning& PC

Non-Conform Product

Request Bill

NCR

Approved
Quality Docket

Customer
Shop
PC Team
Self (QC)
Project Manager
Marketing
Self (QC)
Sub contracting
Laboratory
NDT
Self (QC)
Engineering
(Project Manager)
Engineering
Shop
Quality Manager
Marketing

Supplier

Input

Process

Output

Customer

Marketing

RFQ
Customer Spec. Contract review

Confirmation
of capability

Marketing

Archieve

Standards
(ASTM, CCH )

NDT procedure

Self (NDT)

Planning
and PC

Manufacturing
programme

NDT tests planning

NDT tests
programme

PC Team
Quality Manager

NDT tests

NDT report

Project Manager
Workshop
QC

NDT tests at
subcontractant

NDT report

Quality Control
Project Manager

Presentation of parts at
final inspection (witness)

NDT report

Project Manager
Quality Control

Maintenance of NDT
equipment

Calibration
Request Bill

Quality Control Request Bill

Subcontract

Request of
NDT tests

Quality Control Request Bill

Maintenance

Deadline List
of calibration

NDT procedures
preparing

Laboratory

CUSTOMER
Contract

RFQ

negotiate

NO

MARKETING
cash flow
review

NO

Risk Assessment

first-negotiate

Decision

YES
re-review
RFQ
Estimate Contract Sheet

YES

Estimate Summary Sheet

Technical Approval

ESTIMATION&PC
ENGINEERING
QA&NDT

Kick of Meeting
Confirming consumptions
Estimating lead time
.
Conclusions
(signatures list)

Manufacturing Inspection Plan (MIP)

CUSTOMER

Contract Review

agreement

MARKETING

Contract Transfer

Contract

Planning & PC
Shop Order
Technical Docs
Technical Approval&
Estimation Sheet
Kick of Meeting
Contract

issue MIP

List of documents
and deadlines

Engineering
&QA

MIP
spread

MIP.

MIP

spread

Production Control
planning

manufacturing

Engineering

Surveyor (if case)

technology

notification

Traveller

PRODUCT

delivery

MONITORING
CUSTOMERs
SATISFACTION

CUSTOMER

Claim record
preliminary review
inform top management
milestones

MARKETING

CLAIMs
REVIEW
MEETING

Review..

(a) initial review

CLAIMs
SHEET

QA

QC

PC

Shop

final review
NOT

it is established:
1 root causes

2 technical-economical decision
3 corrective/preventive actions
4 customer communication/negotiate

Approval
TOP
MANAGEMENT
YES

Quality lever

Product
design
Process design

Production
Design for
fewer key
characteristic,
simplicity,
reliability, and
inspectability

customer

Product quality
Use
appropriate
quality
improvement
tools to develop
work
procedures that
reduce
manufacturing
variability and
costs

Follow
procedures
established
during quality
planning.
Control
process by
record onto
TRV

Thank you!