Critique of Process Flow Diagram

John B.

Registered Visitor
#1
Hello all,

I am looking for some constructive criticism on the first two pages of a Process Flow Diagram. This is a new format that our customer is requesting.

Our previous Process Flow Diagrams contained only the process step, description and symbol.

Additional info that might/might not be helpful
1) The part in question might be considered by some to be similiar to a
manual transmission gear.
2) "Wickman" is a six-spindle screw machine.

I can see how this new format will more easily flow into the PFMEA and CP.

Looking forward to your comments/suggestions.

Thanks,
John
 

Attachments

Elsmar Forum Sponsor
V

Valeri

#3
John,

My :2cents:. It looks like they are trying to merge the flow/fmea/control plan and not getting much bang for the buck. I'm at a loss as to why this wheel is being reinvented. Have they changed their fmea or control plan? If they are only using this form, they are missing an enormous amount of information.
 

Miner

Forum Moderator
Staff member
Admin
#4
The main advantage of this process flow format is that it identifies all of the incoming sources of variation, product characteristics and process parameters at each operation. This helps speed up the PFMEA process because you identify potential failure modes for each. This is more efficient and effective than the usual brainstorming approach that many take in the PFMEA.
 

bobdoering

Stop X-bar/R Madness!!
Trusted Information Resource
#5
I like how they treated each tool as a suboperation. It would have been nice to see the inspection section. One thing that is difficult on this style, but handier on the box and arrow type is rework operations. Ok, ok, let's get real, you will have rework - and you know it. Deburr, whatever. Identifying as a part of the process will help you if you have to PPAP, in that if you need to do it you do not need a customer approval each time you do it. Fess it up, tell them how you would rework it, put it in there as a contingency. The style presented is very linear, so it is tougher to deal with decision points. :2cents:
 
V

Valeri

#6
The main advantage of this process flow format is that it identifies all of the incoming sources of variation, product characteristics and process parameters at each operation. This helps speed up the PFMEA process because you identify potential failure modes for each. This is more efficient and effective than the usual brainstorming approach that many take in the PFMEA.
This may help "speed" the FMEA process but are all the risks actually identified, are all process owners involved with this new flow or just a select few? Without a robust FMEA system, you can get yourself into bunches of trouble including liability issues.

John - The customer will get whatever they want. Having said that, however, I have a couple of questions, just out of curiosity, about this "new" process flow; is this an automotive customer and are you still required to produce a FMEA and control plan?

Coury - I did get discussion going:biglaugh:
 

Patricia Ravanello

Quite Involved in Discussions
#7
Hello all,

I am looking for some constructive criticism on the first two pages of a Process Flow Diagram. This is a new format that our customer is requesting.

Our previous Process Flow Diagrams contained only the process step, description and symbol.

Additional info that might/might not be helpful
1) The part in question might be considered by some to be similiar to a
manual transmission gear.
2) "Wickman" is a six-spindle screw machine.

I can see how this new format will more easily flow into the PFMEA and CP.

Looking forward to your comments/suggestions.

Thanks,
John
I have to agree with Bob and Valerie...and.. to reinforce Bob's comment relating to rework, there is no consideration of management of non-conformances which might arise or be identified during the process...While you do identify "inspection" in Operation 20, resultant failures are not accounted for...(or minimally, a link or mention to another process for managing exceptions). Additionally, there is no description of who has responsibility or authority to disposition...or who to contact to disposition, so I wouldn't find this format suitable for a Work Instruction in its current format.

Re: Operation 10 - Receive Material...under Characteristic, you've described an "inspection" activity, which probably belongs under Operation 20. Further to that, what happens if "material" and "Quantity" are not verified?

As identified before...this is somewhat redundant if you are still required to submit a PFMEA and Control Plan. In general, I think it's moving in a desirable direction from the perspective of the operator...but could use further enhancements if it's intended to replace the "Work Instruction" of a sole operator. (Having said that, I find it somewhat confusing that the Operations described are probably being performed by two or more individuals...so it's not just a single "Operator Instruction".

Perhaps this is an improvement from the customer's perspective...I don't know what you were offering them before.

Patricia
 

John B.

Registered Visitor
#8
Man do I love this site! Thanks to all for the critique.

Miner, the “incoming sources of variation” is exactly what our customer is looking for. This is the new part of the process flow for me.

Miner and bobdoering, you are right, there will be rework. I will be adding this contingency to the process flow. Although I am not sure how to do it with this format.

Valeri, yes this is an automotive customer. This process flow will flow into the PFMEA and ultimately the CP. As far as I know the PFMEA and CP have not changed. I believe what the customer is looking for with this new style of process flow is “incoming sources of variation”.

Patricia, yes a PFMEA and CP will be submitted. The “reaction plan” for management of non-conforming parts is on our CP.
This process flow does will not be used as “work instructions”. Individual “work instructions” will be written for each process step. Our previous Process Flow Diagrams contained only the process step, description and symbol.

I will incorporate rework process into this process flow. But, as bobdoering mentioned it would be a lot easier with the old “box and arrow” style process flow.

Any other suggestions?

Thanks to all,
John
 
Thread starter Similar threads Forum Replies Date
Q Process Maps: Sales, different products, more boxes - Critique my map? ISO 9000, ISO 9001, and ISO 9004 Quality Management Systems Standards 5
9 ECR (Engineering Change Request) process - Please critique / review Document Control Systems, Procedures, Forms and Templates 10
Anerol C Please Critique my process map - Metal-Mechanic Industry Process Maps, Process Mapping and Turtle Diagrams 4
M Contract Review Process Turtle Diagram - Please Review and Critique Contract Review Process 18
M Internal Document Request Process - Please Critique ISO 9000, ISO 9001, and ISO 9004 Quality Management Systems Standards 6
C Please Critique my process map - Fiberglass business Process Maps, Process Mapping and Turtle Diagrams 11
Gman2 Please Critique My ISO 9001 Internal Process Audit Plan Process Audits and Layered Process Audits 39
B Seeking Critique: How Does Our Process Map Look? Process Maps, Process Mapping and Turtle Diagrams 5
C Please Critique Our Quality Plan Process Map! Feedback Appreciated! Process Maps, Process Mapping and Turtle Diagrams 16
T Food Safety Manual for ISO 22000:2005 - Please critique Food Safety - ISO 22000, HACCP (21 CFR 120) 2
S Incident Investigation Procedure for Critique Document Control Systems, Procedures, Forms and Templates 3
S Critique of an IMS (Integrated Management Systems) Manual Misc. Quality Assurance and Business Systems Related Topics 1
B Document Control Procedure - Please Critique Document Control Systems, Procedures, Forms and Templates 5
B Document Control Procedure - Critique Wanted Document Control Systems, Procedures, Forms and Templates 5
W Please review and critique our new Document Control Procedure ISO 13485:2016 - Medical Device Quality Management Systems 4
6 ISO 9001 Audit Findings Sept 2011 - Critique and Comments ISO 9000, ISO 9001, and ISO 9004 Quality Management Systems Standards 5
C Quality Awareness Presentation Needs Critique Quality Manager and Management Related Issues 20
P Please critique my Organization Structure Chart ISO 9000, ISO 9001, and ISO 9004 Quality Management Systems Standards 2
A Development Project Template - Please Review and Critique Design and Development of Products and Processes 3
C Document Change Request Flowchart - Please critique Document Control Systems, Procedures, Forms and Templates 32
QMMike Please critique this procedure.... Document Control Systems, Procedures, Forms and Templates 3
I Looking for IT job but no experience!/CV critique please Career and Occupation Discussions 4
S Critique Required on GR&R (Gage R&R) Training Presentation Training - Internal, External, Online and Distance Learning 12
D CAPA (Corrective Preventive Action) Form for critique ISO 9000, ISO 9001, and ISO 9004 Quality Management Systems Standards 8
E Please Critique my Root Cause Corrective Action Form training Problem Solving, Root Cause Fault and Failure Analysis 4
J Resume Critique - Please review my resume Career and Occupation Discussions 5
J Can I get someone to help critique this manual? Quality Management System (QMS) Manuals 19
Anerol C Please critique my ISO 9000 Champion Chart/Owner Chart ISO 9000, ISO 9001, and ISO 9004 Quality Management Systems Standards 6
J Material Handling Plan as Described in v5.5 of the PSO Document - Please critique Customer and Company Specific Requirements 3
Anerol C Please Review and Critique my Metal Fabrication Industry Quality Manual ISO 9000, ISO 9001, and ISO 9004 Quality Management Systems Standards 12
S Please Critique my Quality Manual - Media/Administration company. ISO 9000, ISO 9001, and ISO 9004 Quality Management Systems Standards 11
Anerol C Please critique my plant turtle maps.... Process Maps, Process Mapping and Turtle Diagrams 22
S Design and Development Activities Flow - Please Critique Design and Development of Products and Processes 3
M Control Of Documents - Document Control System Design Critique Wanted - TS16949 Document Control Systems, Procedures, Forms and Templates 12
apestate Micrometer Calibration Procedure - Please critique General Measurement Device and Calibration Topics 20
T EMS Objectives, Targets and Programme(s) - I have put together a list for critique Miscellaneous Environmental Standards and EMS Related Discussions 10
C My Product Realization Map - Please Critique ISO 9000, ISO 9001, and ISO 9004 Quality Management Systems Standards 3
C Product Realization Map attached - Please Critique ISO 9000, ISO 9001, and ISO 9004 Quality Management Systems Standards 13
B Quality Policy - A Critique Request ISO 9000, ISO 9001, and ISO 9004 Quality Management Systems Standards 23
K ISO 9001 Quality Policy Content Critique and Extended Discussion ISO 9000, ISO 9001, and ISO 9004 Quality Management Systems Standards 37
M Hiring Decisions - How much effort do you put into the hiring process these days? (7/2020) Misc. Quality Assurance and Business Systems Related Topics 4
hockeyhead Existing process never included in AS9100 scope of certification AS9100, IAQG 9100, Nadcap and related Aerospace Standards and Requirements 9
A What is the difference between Design Process, Process Design and Design Control? 21 CFR Part 820 - US FDA Quality System Regulations (QSR) 2
V Process, component or full product re-qualification: leaded to unleaded solder Qualification and Validation (including 21 CFR Part 11) 7
C Refreshing an old and boring topic - Job descriptions and Roles vs Process Documentation ISO 9000, ISO 9001, and ISO 9004 Quality Management Systems Standards 9
R Where does IATF 16949 address Process mapping? IATF 16949 - Automotive Quality Systems Standard 3
C OEE and In-process Inspection Manufacturing and Related Processes 2
S Effective nonconforming process for AS9100 8.7 AS9100, IAQG 9100, Nadcap and related Aerospace Standards and Requirements 6
T ISO 13485 - Process validation at critical suppliers ISO 13485:2016 - Medical Device Quality Management Systems 7
K Software Validation for Measurement Tools used in Process Validation ISO 13485:2016 - Medical Device Quality Management Systems 2
Similar threads


















































Top Bottom