GM

Training Workshop on

Preparation of Process Flow Chart

 Preparation of Process Flow Chart

Definition & Functions of a Process Flow

Document

A process Flow document provides a visual

representation of a process.
Or
It’s a pictorial presentation of how the process/Operation
of any component flows for addition of value into the
product
It also captures, in a standardized format, auxiliary
information associated with the various steps of the
process, including….

Global Management - Kolhapur / Pune

 Preparation of Process Flow Chart

Definition & Functions of a Process Flow

Document

a.Operation Number and Description

b.Incoming sources of Variation
c.A diagrammatic Representation of the Process
d.Product Characteristics
e.Process Characteristics

Global Management - Kolhapur / Pune

 Preparation of Process Flow Chart

BENEFITS OF PROCESS FLOW

a.It Shows entire Process at Once

b.It allows each operation to be questioned.
c.It exposes sources of Variation
d.It highlights non-value added steps, including
• possible process simplifications.
•unnecessary movements of parts and materials
•unnecessary handling, inspection, and stores.

Global Management - Kolhapur / Pune

 Preparation of Process Flow Chart

BENEFITS OF PROCESS FLOW

• It can be used as a tool in many contexts.

• Bottleneck Analysis
• As a foundation for remaining process review
documents….
• Process FMEA
• Control Plan

Global Management - Kolhapur / Pune

 Preparation of Process Flow Chart

BENEFITS OF PROCESS FLOW

“CONSTRUCTING THE DETAILED PROCESS FLOW

DOCUMENT IS THE FIRST STEP IN DEVELOPING A
CONTROL STRATEGY”

Global Management - Kolhapur / Pune

 Preparation of Process Flow Chart

PROCESS FLOW INPUTS

• Customer Prints
• Plant Layout
• Problem Reports and Logs
• A baseline knowledge of each process
• Useful information can be derived from….
a.Set Up Instructions
b. Existing Work Instructions
c. Existing Process Flows
d. Maintenance History

Similar Parts or Assemblies

Global Management - Kolhapur / Pune

 Preparation of Process Flow Chart

WHO SHOULD DO THE PROCESS FLOW

DOCUMENT

• To be prepared by CFT/MDT

Team Consists of Representatives from production,

Q.A., Engineering, Marketing, Despatch, Purchase &
Suppliers

Global Management - Kolhapur / Pune

 Preparation of Process Flow Chart

PREPARATION OF PROCESS FLOW DOCUMENT

OPERATION OPERATION INCOMING SOURCE OF PROCESS FLOW PRODUCT PROCESS

NUMBER DESCRIPTION VARIATION DIAGRAM CHARACTERISTICS CHARACTERISTICS

Global Management - Kolhapur / Pune

 Preparation of Process Flow Chart

PREPARATION OF PROCESS FLOW DOCUMENT

OPERATION OPERATION INCOMING SOURCE OF PROCESS FLOW PRODUCT PROCESS

NUMBER DESCRIPTION VARIATION DIAGRAM CHARACTERISTICS CHARACTERISTICS

Global Management - Kolhapur / Pune

 Preparation of Process Flow Chart

PREPARATION OF PROCESS FLOW DOCUMENT

OPERATION OPERATION INCOMING SOURCE OF PROCESS FLOW PRODUCT PROCESS

NUMBER DESCRIPTION VARIATION DIAGRAM CHARACTERISTICS CHARACTERISTICS

Global Management - Kolhapur / Pune

 Preparation of Process Flow Chart

PREPARATION OF PROCESS FLOW DOCUMENT

SYMBOL DESCRIPTION

OPERATION OR Machine

OPERATION WITH AUTOMATIC INSPECTION

INSPECTION

TRANSPORATION OR FLOW OR MOVEMENT

STORAGE

PRIMARY PATH

ALTERNATE PATH

Global Management - Kolhapur / Pune

 Preparation of Process Flow Chart

PREPARATION OF PROCESS FLOW DOCUMENT

OPERATION OPERATION INCOMING SOURCE OF PROCESS FLOW PRODUCT PROCESS

NUMBER DESCRIPTION VARIATION DIAGRAM CHARACTERISTICS CHARACTERISTICS

Global Management - Kolhapur / Pune

 Preparation of Process Flow Chart

PREPARATION OF PROCESS FLOW DOCUMENT

OPERATION OPERATION INCOMING SOURCE OF PROCESS FLOW PRODUCT PROCESS

NUMBER DESCRIPTION VARIATION DIAGRAM CHARACTERISTICS CHARACTERISTICS

Global Management - Kolhapur / Pune

Preparation of Process Flow Chart

Global Management - Kolhapur / Pune