2-1

Define Process
The
Quality
Improvement
Model
Use SPC to
Maintain
Current
Process
Collect &
Interpret
Data
Select
Measures
Define
Process
Is
Process
Capable
?
Improve
Process
Capability
Is
Process
Stable
?
Investigate &
Fix Special
Causes
No
Yes
No
Yes
Define Process
Purpose:
Communicate to an
individual or team a clear
understanding of the process
under study.
Establish improved and
consistent process
operations.
2-2
Define Process
Process Components
Suppliers
Inputs
Processes
Outputs
Customers
A process is any activity that converts
All processes involve Suppliers, Inputs, Outputs, and
Customers
2-3
Define Process
Defining Processes
Communicate to an individual or a
team a clear understanding of the
process under study.
Standardize process operations.
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.

Why
How
2-4
Define Process
Process Standardization
STANDARDIZATION is everyone following the
procedures the same way.
It is neither possible nor necessary to standardize all
the operations. However, crucial elements...should be
measurable and standardized.
Misaaki Imai
KAIZEN
Are not the optimum perfection.
Are not necessarily the current best known
methods.
Are the agreed-upon methods.
These Procedures:

2-5
Define Process
A Graphical
display of the
steps in a process.
Purchasing Process
Standard Symbols
Process Steps
Decisions
Beginning or End Points,
or Connectors between pages
Manufacturing Submits
Purchase Order
Purchasing Contacts
Vendors for Pricing
Vendor Submits Bids
Vendor Delivers Goods
Manufacturing Inspects
Goods
Purchasing Pays Vendor
Can Vendor
Meet Schedule?
No
Yes
End
Discuss Quality vs. Price
and Select Vendor
Process Flow Charts
2-6
Define Process
Pumping
Filtration
Extrusion
String Up
Quench
Cutting
Outputs
Chip weight
Chip viscosity Chip
defects
Gels Dirt
Shutdown/rate
Process Mapping
2-7
Define 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 (Xs)
Output variables (Ys)
Data collection points
When do you apply process mapping?
Always

Detailed Process Maps
2-8
Define 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
Process Mapping Steps
2-9
Define 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
2-10
Define Process
Manufacturing
Fluid Bed Dryer
Rate
Temperature
Air Flow
Residence Time


Appearance (Color )
Physical Chem
Properties
Cycle Time
(plugging)
Zone 3 Temp
Inputs Outputs
Order Entry
Phone
FAX
Email
Price
Availability
Confirmation of
Order
Promise Date
Order number
Inputs Outputs
Non- Manufacturing
Step 1: Examples
2-11
Define Process
Include all value-added and non value-added steps
Process steps, inspection/test, rework, scrap points
Manufacturing
Answer Phone
Greet customer
Determine parts needed
Identify need date
Identify ship to address
Identify price
Identify shipment method
Internal Information
Get internal P/N
Determine terms
Identify lead time
Complete order
worksheet
Order Entry
Input information
Print order confirmation
Determine ship date
Review order
Order Confirmation
FAX confirmation to
customer
Verify manufacturing
receipt of order
Non-Manufacturing
Mixing
Water and
Metals
Preparation
Extrusion
Extrude
through die
Dryer
Calciner

NADM
Solution
Preparation
Impregnation
Metals
addition
Fluid Bed
Dryer
Final
preparation /
appearance
issues
Material
drying, surface
area issues
Step 2: Identify All Steps in the Process
2-12
Define Process
Include both process and product output variables
Manufacturing
Outputs Outputs
TV of Mix -
Quality
Check
around
extrusion


TV of Mix -
Quality
Check
around
extrusion




Surface Area

Pore Volume

Appearance
pH
Temp
Specific Gravity
Clarity




Appearance
(Color,
Wetness)



Appearance
(Color)
Physical
Chemical
Properties
Cycle Time
(plugging)
Zone 3 Temp
Mixing
Water and
Metals
Preparation
Extrusion
Extrude
through die
Dryer
Calciner

Material
drying, surface
area issues
NADM
Solution
Preparation
Impregnation
Metals
addition
Fluid Bed
Dryer
Final
preparation /
appearance
issues
Step 3: List Key Output Variables
2-13
Define Process
Include both process and product output variables
Prompt
answer
Live body
Part number
Availability
Need date
Customer
number
Order
worksheet
Pricing
Non-Manufacturing
Outputs
Answer Phone
Greet customer
Determine P/N
Identify need date
Identify ship to address
Identify ship method
Internal Information
Get internal P/N
Determine terms
Identify lead time
Complete order
worksheet
Outputs
Order in
computer
All line
items
complete
Correct info
Promise
date
Order
number
Printed
confirmation
Order
confirmation
to customer
Order to
production
Order Entry
Input information
Print order confirmation
Determine ship date
Review order
Order Confirmation
FAX confirmation to
customer
Verify manufacturing
receipt of order
Step 3: List Key Output Variables
2-14
Define Process
List all key input variables and classify them as
Controlled inputs
Uncontrolled inputs
Controlled Inputs: Input variables that can be changed to see
the effect on output variables
Sometimes called knob variables
Uncontrolled 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: Input variables that have been statistically
shown to have a major impact on the variability of the output
variables
Step 4: List and Classify Key Input Variables
2-15
Define Process
Manufacturing
Outputs Outputs
TV of Mix -
Quality
Check
around
extrusion


TV of Mix -
Quality
Check
around
extrusion




Surface Area

Pore Volume

Appearance
pH
Temp
Specific Gravity
Clarity




Appearance
(Color,
Wetness)



Appearance
(Color)
Physical
Chemical
Properties
Cycle Time
(plugging)
Zone 3 Temp
Mixing
Water and
Metals
Preparation
Extrusion
Extrude
through die
Dryer
Calciner

Material
drying, surface
area issues
NADM
Solution
Preparation
Impregnation
Metals
addition
Fluid Bed
Dryer
Final
preparation /
appearance
issues
Total Rate C
Mixer Speed C
Al2O3 Qual U
Rec Comp U


Ext Rate C
Die Wear U
Ext RPMs C
Die Change U




Temperature C
Rot speed C
Draft C
Feed Rate C
Drying air U
Inputs Types Inputs Types
Nitric Acid C
H2O2 C
Water C
ADM C
Hold Time U
Agitation C

Phos Acid C
Nozzle Type C
Spray Time C
Water C
Moly C
Nickel C
Base C


Temperature C
Rate C
Air Flow C
Res Time C
Process Mapping Examples
2-16
Define Process
Non-Manufacturing
Outputs
Answer Phone
Greet customer
Determine P/N
Identify need date
Identify ship to address
Identify ship method
Internal Information
Get internal P/N
Determine terms
Identify lead time
Complete order
worksheet
Order Entry
Input information
Print order confirmation
Determine ship date
Review order
Order Confirmation
FAX confirmation to
customer
Verify manufacturing
receipt of order
Inputs Type
Order
worksheet
Computer
entry screens
Lead time
information
from mfg
Shipment
method
Printed
confirmation
sheet
Production
schedule
Customer
contact info
Production
contact info
Confirmation
procedure
U

C

U


C
C


U

C

C

C
Inputs Type
Information
from customer
Greeting script
Answering
procedure
Telephone
system
Cross
reference for
P/Ns
Order
information
Plant loading
information
Order
worksheet
form
Pricing
algorithm
C

C
C

U
C


U

U

C


C
Prompt
answer
Live body
Part number
Availability
Need date
Customer
number
Order
worksheet
Pricing
Outputs
Order in
computer
All line
items
complete
Correct info
Promise
date
Order
number
Printed
confirmation
Order
confirmation
to customer
Order to
production
Process Mapping Examples
2-17
Define Process
Controlled Input
Variable
Target
Upper
Spec
Lower
Spec
Die Wear ? ? ?
Solvent Type ? ? ?
Ram Speed ? ? ?
Clamping Force ? ? ?
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!
Step 5: Add Specifications for Inputs
2-18
Define 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