Process flow and process chart

I made a ppt. on fiction project. Here I have shown Process flow diagram with its questions and solution to make better process flow chart and diagram.Understand this you'll understand whole process flow diagram and deep detail about bottlenecks in manufacturing process.

1. Made by:- Parvesh Mittal

2. Process chart Graphical  representation of the sequence of steps or tasks (workflow) constituting a process, from raw materials through to the finished product It  serves as a tool for examining the process in detail to identify areas of possible  improvements Also known as  process  map

3. Process Chart Symbols Symbols Name Action Examples Operation Add Value Saw, Cut, Paint, Packaging Transport Moves Some Distance Convey, Truck Inspect Checks For Defects Visual Inspect, Dimension Inspect Delay Temporary Delay/Hold WIP Hold, Queue Storage Warehouse Warehouse or Tracked Storage Location Handle Transfer Or Sort Re-Package, Transfer To Conveyor Decide Make A Decision Approve/Deny Purchase

4. Operation A large circle indicates operation An operation takes place when there is a change in physical or chemical characteristics of an object. An assembly or disassembly is also an operation A main step, where the part, material or product is usually modified or changed

5. Transportation An arrow indicates transport. It refers to the movement of an object or equipment from one place to another. E.G. Moving the material by a trolley operator going to the stores to get some tool

6. Inspection A square indicates inspection. This is the time spent inspecting raw materials, work-in-process, and finished goods, possibly at multiple stages of the production process. E.G. Checking the diameter of a rod.

7. Delay Move time:- This is the time required to move items into and out of the manufacturing area, as well as between workstations within the production area Queue time:- This is the time spent waiting prior to the processing, inspection, and move activities Example:- An operator waiting to get a tool in the stores Worked pieces stocked near the machine before the next operation

8. Storage An equilateral triangle standing on its vertex represents storage Storage takes place when an object is stored and protected against unauthorized removal Example:- Raw material in the store room

9. VAA & NVA Value added activity Providing worth or merit to an activity as defined by the customer. Activities must be performed to meet customers CTQ’s. Actions are value added if the customer cares, if something is physically changing for the best and you do the step right the first time. Value added activities essentially change the product or service and the customer is willing to pay for them .   Non value added activity No merit or worth to an activity as defined by the customer. The activity does not need to be done to generate output. It does not add value to the service or product. In essence it is something the customer is not willing to pay for. Non value added activities forces us to be inefficient while generating output .

10. Some examples of non-value added activities Bottle necks on production lines Too much sampling and testing Unorganized work areas and lack of housekeeping Too much “travel distance/time” due to poor lay out on shop floor Reworks and sorting defect material Not doing things right the first time Unnecessary equipment stoppages or manufacturing downtime Lack of materials or manpower hindering operation flow Unlabeled or unidentifiable material Running out of consumables (order in advance) Too long or insufficient set up times TIMWOOD seven wastes: Transportation, Inventory, Movement, Waiting, Over processing, Overproduction, Defects

11. Process flow diagram A  process flow diagram (PFD) is a diagram commonly used in chemical and process engineering to indicate the general flow of plant processes and equipment. The PFD displays the relationship between major equipment of a plant facility and does not show minor details such as piping details and designations . Another commonly used term for a PFD is a flow sheet .

12. Assembly Flow Diagram 1 3 A1 A5 5 A4 6 2 4 I1 I4 I5 I3 A3 A2 I2

13. When to use it It is used when observing a physical process, to record actions as they happen and thus get an accurate description of the process. It is used when analyzing the steps in a process, to help identify and eliminate waste - thus, it is a phenomenal tool when it comes to efficiency planning. It is used when the process is mostly sequential, containing few decisions .

14. Process Flow Chart What you think it is… What it actually is… What you would like it be…

15. Required Assembly Tasks

16. Findings Elements Present method Steps Time allotted Operation & transportation 10 37 min. Inspection 4 16 min. Total 14 53 min. Value Added Time: {Operation time / Total Time} = 37/53 69.81%

17. Inbound Logistics We are using vertical integration of supply chain. We have merged with our suppliers and fixed a quality standard for our product. We are in contract with our suppliers that if the product delivered is not of the quality which we have selected whole consignment will be refused. We have got our raw material insured so that if they are damaged/ lost in transit we will have protection against the loss.

18. Inbound Logistics… We have integrated automatic ordering and order fulfillment systems in our assembly lines so that delay times can be reduced so our production line continues to operate with any not haul. We are using our own fleet to bring raw materials from suppliers. We stocking our raw materials in our store so that in case of more demand of them we can procure from there.

19. Outbound Logistics We have divide North, south, Central, east, west Side. As North Zone, South Zone, Central Zone, East Zone, West Zone. We have our offices/ storage facilities in all the 5 zones, and our branch office in the main cities of all the states. We use air, road transport for outbound logistics.

20. Proposed Method

21. Findings Elements Proposed method Steps Time allotted Operation & transportation 10 37 min. Inspection 2 6 min. Total 14 43 min. Advantage Time Saving Increased Production High Quality Disadvantage High Skilled Labor New Technology

22. Summary Elements Present method Proposed method Difference Steps Time allotted Steps Time allotted Steps Time allotted Operation & transportation 10 37 min. 10 37 min. 2 min. Inspection 4 16 min. 2 6 min. 2 10 min. Total 14 53 min. 14 43 min. 7 10 min.

23. Bottleneck (Production)  A bottleneck is one process in a chain of processes, such that its limited capacity reduces the capacity of the whole chain The result of having a bottleneck are stalls in production, supply overstock, pressure from customers and low employee morale Short and long-term bottlenecks Short-term bottlenecks are temporary and are not normally a significant problem. An example of a short-term bottleneck would be a skilled employee taking a few days off. Long-term bottlenecks occur all the time and can cumulatively significantly slow down production. An example of a long-term bottleneck is when a machine is not efficient enough and as a result has a long queue

24. Bottleneck (Production )… Manufacturing throughput time is the amount of time required for a product to pass through a manufacturing process, thereby being converted from raw materials into finished goods. The concept also applies to the processing of raw materials into a component or sub-assembly The time required for something to pass through a manufacturing process covers the entire period from when it first enters manufacturing until it exits manufacturing

25. Throughput time Processing time :-Time spent transforming raw materials into finished goods. Inspection time :- Time spent inspecting raw materials, work-in-process, and finished goods, possibly at multiple stages of the production process. Move time :- Time required to move items into and out of the manufacturing area, as well as between workstations within the production area. Queue time :- Time spent waiting prior to the processing, inspection, and move activities.

26. Process Flow Diagram Symbols - Instruments Process Flow Diagram use symbols and circles to represent each instrument and how they are inter-connected in the process .

27. Process Flow Diagram Symbols - Equipment Compressor  is a mechanical device that takes in a medium and compresses it to a smaller volume. A mechanical or electrical drive is typically connected to a pump that is used to compress the medium. Pump  refers to a mechanical apparatus using suction or pressure to raise or move liquids, compress gases, or force air into inflatable objects such as tires. The symbols for pumps may closely resemble those for compressors. Mixing vessel  is a container that is used to blend several components together.

28. Indicator  is a thing that indicates the state or level of something. Flow transmitter  is a device used as a means of measuring the flow of a specific substance, usually liquid, through a series of pipelines or tubing . Pressure transmitter  is used to measure pressure, typically of gases or liquids. Pressure recorder , as its name implies, is used to record the pressure . Process Flow Diagram Symbols(Equipment)…