Define Process

The Define
Process
Quality
Improvement Select
Measures

Model
Collect &
Interpret
Data

Define Process Is
No Investigate &
Process
Fix Special
Stable
Causes
?
Purpose:
Communicate to an Yes
individual or team a clear
No Is
understanding of the process Improve
Process
Process
Capable
under study. Capability
?

Establish improved and Yes

consistent process Use SPC to
Maintain
operations. Current
Process

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 Define 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 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 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 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 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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 Define Process
Detailed Process Maps
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

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 Define Process
Process Mapping Steps

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 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 Process
Step 1: Examples
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 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 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

Extrusion TV of Mix - Impregnation Appearance

Quality
Extrude (Color,
Check
through die Metals Wetness)
around
extrusion addition

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

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 Define Process
Step 3: List Key Output Variables
Include both process and product output variables

Non-Manufacturing
Outputs Outputs
Answer Phone Order Entry Order in
Prompt
Greet customer Input information computer
answer
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 Process

Step 4: List and Classify Key Input Variables

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
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Process Mapping Examples Define Process

Manufacturing
Inputs Types Outputs Inputs Types Outputs

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

Ext Rate C
Extrusion TV of Mix - Phos Acid C
Impregnation
Nozzle Type C Appearance
Die Wear U Quality
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
Final Properties
Feed Rate C Material Pore Volume Air Flow C preparation / Cycle Time
Drying air U drying, surface Res Time C appearance (plugging)
area issues Appearance
issues Zone 3 Temp

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 Define Process

Process Mapping Examples

Non-Manufacturing
Inputs Type Outputs Inputs Type Outputs
Answer Phone Order U Order Entry
Information C Order in
Prompt worksheet
from customer Greet customer Input information computer

answer Computer C
Greeting script C Determine P/N Print order confirmation All line
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
Correct info
Telephone U
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/Ns Printed C
Get internal P/N number FAX confirmation to confirmation
confirmation
Order U Determine terms Order
customer 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
Order C
C
contact info
worksheet
form Production C
contact info
Pricing
algorithm C Confirmation
C
procedure
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 Define Process
Step 5: Add Specifications for Inputs
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 ? ? ?

2-17
 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

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