Define

DefineProcess
Process

The Define
Define
Quality Process
Process

Improvement Select
Measures

Model
Collect &
Interpret
Data

Define Process Is
Investigate &
Process No
Stable Fix Special
Causes
?
Purpose:
• Communicate to an Yes

individual or team a clear Is

Improve No
understanding of the process Process
Process
Capable
Capability
under study. ?

• Establish improved and Yes

consistent process Use SPC to
Maintain
operations. Current
Process

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 Define
DefineProcess
Process

Process Components

Inputs Outputs
Suppliers Processes Customers

 A process is any activity that converts

 All processes involve Suppliers, Inputs, Outputs, and Customers

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 Define
DefineProcess
Process

Defining Processes

Why  Communicate to an individual or a

team a clear understanding of the
process under study.
 Standardize process operations.

How  Identify and list Suppliers, Inputs,

Outputs, and Customers.
 Develop flow chart of the process steps.
 Assure a common understanding of
related procedures.
 Verify practice vs. procedure.
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 Define
DefineProcess
Process

Process Standardization
STANDARDIZATION is everyone following the
procedures the same way.

These Procedures:
 Are not the optimum perfection.
 Are not necessarily the current best known methods.
 Are the agreed-upon methods.

“It is neither possible nor necessary to standardize all

the operations. However, crucial elements...should be
measurable and standardized.”
—Misaaki Imai
KAIZEN
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 Define
DefineProcess
Process

Process Flow Charts Purchasing Process

Manufacturing Submits
Purchase Order

A Graphical Purchasing Contacts

Vendors for Pricing
display of the
steps in a process. Vendor Submits Bids

Discuss Quality vs. Price

and Select Vendor
Standard Symbols
Can Vendor No
Process Steps Meet Schedule?

Yes
Decisions Vendor Delivers Goods

Manufacturing Inspects
Beginning or End Points, Goods
or Connectors between pages
Purchasing Pays Vendor

End
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 Define
DefineProcess
Process

Process Mapping

Pumping String Up

Outputs
Chip weight
Chip viscosity Chip
Filtration Quench defects
Gels Dirt
Shutdown/rate

Extrusion Cutting

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Detailed Process Maps Define
DefineProcess
Process

 What is the tool?

 Graphical illustration of the process
 What will the tool identify?
 All value-added and non-value-
added process steps
 Input variables (X’s)
 Output variables (Y’s)
 Data collection points
 When do you apply process mapping?
 Always

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Process Mapping Steps Define
DefineProcess
Process

1. Identify the process, its external inputs

and customer outputs
2. Identify all steps in the process graphically
3. List output variables at each step
4. List input variables and classify process
inputs as controlled or uncontrolled
5. Add process specifications for input
variables

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 Define
DefineProcess
Process

Step 1: Identify the Process and

Inputs/Outputs
 We need to get a 50,000 ft. view of the process first
 First identify the process in simple terms
 Secondly we identify external inputs
o Incoming information
o Raw materials
o Personnel
o Energy requirements
 Finally we identify the customer requirements
(outputs)
o Identify the attributes of a correctly functioning product or service

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 Define
DefineProcess
Step 1: Examples Process

Manufacturing
Inputs Outputs
Fluid Bed Dryer
Rate Appearance (Color)
Temperature Physical Chem
Air Flow Properties
Residence Time Cycle Time
(plugging)
Zone 3 Temp

Non- Manufacturing
Inputs Outputs
Order Entry
Phone Price
FAX Availability
Email Confirmation of
Order
Promise Date
Order number
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 Define
DefineProcess
Process

Step 2: Identify All Steps in the Process

 Include all value-added and non value-added steps
 Process steps, inspection/test, rework, scrap points

Manufacturing
Mixing Extrusion Dryer NADM Impregnation Fluid Bed
Calciner Dryer
Water and Extrude Solution Metals
Material Final
Metals through die Preparation addition
drying, surface preparation /
Preparation
area issues appearance
issues

Non-Manufacturing
Answer Phone Internal Information Order Entry Order Confirmation
Greet customer Get internal P/N Input information FAX confirmation to
Determine parts needed Determine terms Print order confirmation customer
Identify need date Identify lead time Determine ship date Verify manufacturing
Identify ship to address Complete order Review order receipt of order
Identify price worksheet
Identify shipment method

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 Define
DefineProcess
Process
Step 3: List Key Output Variables
 Include both process and product output variables
Manufacturing
Outputs Outputs
Mixing NADM • pH
• TV of Mix
Water and Solution • Temp
-Quality
Metals Preparation • Specific Gravity
Check
Preparation • Clarity
around
extrusion

• TV of Mix -
Extrusion Impregnation • Appearance
Quality
Extrude (Color,
Check
through die Metals Wetness)
around
extrusion addition

• Appearance
(Color)
Dryer Fluid Bed • Physical
• Surface Area
Calciner Dryer Chemical
• Pore Volume Final Properties
Material preparation / • Cycle Time
drying, surface appearance (plugging)
area issues • Appearance
issues • Zone 3 Temp

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Step 3: List Key Output Variables Define
DefineProcess
Process

 Include both process and product output variables

Non-Manufacturing
Outputs Outputs
Answer Phone Order Entry • Order in
• Prompt
• Greet customer answer • Input information computer
• Determine P/N • Live body • Print order confirmation • All line
• Identify need date • Determine ship date items
• Part number
• Identify ship to address • Review order complete
• Availability
• Identify ship method • Correct info
• Need date
• Promise
date
• Order
number
• Printed
confirmation
Internal Information • Customer Order Confirmation • Order
• Get internal P/N number • FAX confirmation to confirmation
• Determine terms • Order customer to customer
• Identify lead time worksheet • Verify manufacturing • Order to
• Complete order • Pricing receipt of order production
worksheet

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 Define
DefineProcess
Process

Step 4: List and Classify Key Input Variables

 List all key input variables and classify them as
 Controlled inputs
 Uncontrolled inputs

Controlled Inputs:
Inputs Input variables that can be changed to see
the effect on output variables
Sometimes called “knob” variables
Uncontrolled Inputs:
Inputs Input variables that impact the output
variables but are difficult or impossible to control (may also
be controllable, just not under control currently)
Example: Environmental variables such as humidity
Critical Inputs:
Inputs Input variables that have been statistically
shown to have a major impact on the variability of the
output variables
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Process Mapping Examples Define
DefineProcess
Process

Manufacturing
Inputs Types Outputs Inputs Types Outputs

Mixing NADM • pH
Total Rate C • TV of Mix Nitric Acid C
Water and Solution • Temp
Mixer Speed C -Quality H2O2 C
Metals Preparation • Specific Gravity
Al2O3 Qual U Check Water C
Preparation • Clarity
Rec Comp U around ADM C
extrusion Hold Time U
Agitation C

Ext Rate C • TV of Mix - Phos Acid C

Extrusion Impregnation • Appearance
Die Wear U Quality Nozzle Type C
Extrude Spray Time C (Color,
Ext RPMs C Check
through die Metals Wetness)
Die Change U around Water C
extrusion Moly C addition
Nickel C
Base C
• Appearance
(Color)
Temperature C • Physical
Dryer • Surface Area Fluid Bed
Rot speed C Temperature C
Calciner Dryer Chemical
Draft C Rate C Properties
• Pore Volume Final
Feed Rate C Material Air Flow C • Cycle Time
preparation /
Drying air U drying, surface Res Time C appearance (plugging)
area issues • Appearance
issues • Zone 3 Temp

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 Define
DefineProcess
Process
Process Mapping Examples
Non-Manufacturing
Inputs Type Outputs Inputs Type
Outputs
• Information Answer Phone • Order U Order Entry
C • Order in
• Prompt worksheet • Input information
from customer • Greet customer computer
• Determine P/N
answer • Computer C • Print order confirmation • All line
• Greeting script C
• Identify need date • Live body entry screens • Determine ship date
• Answering C items
procedure • Identify ship to address • Part number • Lead time U • Review order complete
• Identify ship method • Availability information
• Telephone U • Correct info
• Need date from mfg
system • Promise
• Shipment C
date
method
• Order
number
• Printed
• Cross C confirmation
reference for Internal Information • Customer Order Confirmation • Order
P/N’s • Printed C
• Get internal P/N number • FAX confirmation to confirmation
• Order confirmation customer
U • Determine terms • Order to customer
sheet • Verify manufacturing
information • Identify lead time worksheet • Order to
• • Production U receipt of order
• Plant loading U Complete order
• Pricing production
worksheet schedule
information
• Customer C
• Order
C contact info
worksheet
form • Production
C
• Pricing contact info
algorithm C • Confirmation
C
procedure
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Step 5: Add Specifications for Inputs Define
DefineProcess
Process

 For input variables identified as Controlled and Critical

Inputs, we can add the operational specifications and
targets for these variables
 This information is the beginnings of the Control Plan!

Controlled Input Upper Lower

Target
Variable Spec Spec

Die Wear ? ? ?

Solvent Type ? ? ?

Ram Speed ? ? ?

Clamping Force ? ? ?

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 Define
DefineProcess
Process

Using Process Maps to Evaluate

Processes

 Understand customer/supplier relationships

 Discover unnecessary steps
 Achieve agreement on process
 Everyone understands their role
 Provides inputs to Cause and Effects Matrix
 Provides inputs to Control Plan Summary
 Provides inputs to Capability Summary
 Excel template: Process Map Master.XLS

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