Process Flow Diagrams

February 17, 2012 Leave a Comment

Several customers have asked recently about an AIAG standard for process flow diagrams.  While there is no standard template within the AIAG core tools (blue manuals), there are guidelines within the APQP manual that automotive organizations should adhere to.

The AIAG – APQP Manual (Second Edition), section 3.3 states, “The process flow chart is a schematic representation of the current or proposed process flow.  It can be used to analyze sources of variation of machines, materials, methods, and manpower from the beginning to end of a manufacturing or assembly process.  It is used to emphasize the impact of sources of variation on the process.”  The flow chart helps to analyze the total process rather than individual steps in the process.  The flow chart assists the organization’s product quality planning team to focus on the process when conducting the PFMEA and designing the Control Plan.

The Process Flow Chart Checklist below can be used by the organization’s product quality planning team to verify completeness or set a standard within the organization for basic flow chart requirements.

Image

The following shapes are typically used to illustrate various process steps within a flowchart.

• Operation (circle) – Value-added manufacturing step
• Transport (arrow) – Movement of product or components from one operation step to the next
• Inspection (square) – Product or process inspection step
• Storage (triangle) – Component or part storage
• Combination: Inspection & Operation (square & circle) – Value-added manufacturing step with distinct product or process inspection steps with variable output data
• Delay – Designed delay that is part of the process

Software Tip: These shapes can be found in the Microsoft Visio “Process Flow” or Microsoft Powerpoint Insert > Shapes menus.

Microsoft also has a site full of FREE templates that can be downloaded for a variety of different flowchart uses.

Happy flow-charting!

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SIPOC vs. Turtle

October 6, 2011 Leave a Comment

SIPOC Part I of II

Ok… Ok… Geez people!  Who would have known that a flippin’ TURTLE diagram could cause such a stir.  So far this month, I’ve been yelled at by a Brit, received kind comments from my Indian friends and told that my system is in shambles – ALL DUE TO THE USE OF TURTLE DIAGRAMS!  Honestly guys, I will admit that I’m a quality geek from time to time, but I don’t care enough about any process improvement tool to start a fight over it.  Ok… that’s a stretch.  But I can honestly say that I never knew that something called a “turtle” could cause such internet traffic and conference room debates.  I will offer this opportunity for those that find it difficult to image the benefit of something as simple as a high-level process flowchart (i.e turtle diagram).  It’s called a SIPOC diagram.  If you don’t like this either, then maybe the problem is YOU… that’s all I’m sayin’.

SIPOC is short for Supplier, Inputs, Process, Outputs & Customer.  SIPOC  is one of many process mapping tools used to inventory all of the influencers that could have an impact on a process you are trying to control.

  • Supplier – who are the internal and/or external suppliers of the process (material or data)?
  • Inputs – what are the inputs or triggers that prompt your process to act (material or data)?
  • Process – this is the process at hand that you are trying to illustrate for control or improvement
  • Outputs – what are the outcomes or results of your process (material or data)?
  • Customer – who is the internal and/or external customer(s) of your process that receive the outputs (material or data)?

For a more complex analysis of process influencers and impacts, the SIPOC diagram can be partitioned into various categories, similar to a fishbone diagram.  The illustration below prompts a process owner to consider elements such as the environment or “man” as having an effect on the performance of a process.

Management can use this tool to define relationships and expectations within the organization.  The SIPOC can also be used to analyze the variables that are not allowing the process to perform as well as expected.

Check back an examples of how this tool can be used to address order inaccuracies at ACME Burger Company and a link to our downloadable SIPOC tool in our next blog.

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Turtle Diagrams (via Concentric Management Systems, Inc.)

August 25, 2011 Leave a Comment

After reviewing statistics from our website dashboard this morning, we were surprised to see that the #1 driver to our website is a search for the words “Turtle Diagrams”. Special thanks to our friend – the turtle!

For years now we have heard a handful of our customers fight with the concept of using a turtle diagram. Recently, I was in a heated discussion with an Engineering Manager who felt very strong about his position that “…turtle diagrams are a waste of time because they are only used during audits… to help an auditor be more efficient in his audit of us”.

Well… yeah. I mean, PERFECTLY said (and thanks for making the argument easier for me Mr. Resister!). Turtle Diagrams at this organization were often only used by the auditors. But that doesn’t mean that they were intended for the auditors. They were INTENDED for processes owners; a 1-page diagram that should be used to keep them on track with the expected outputs of the process they are responsible for. (Note: I said “process” they are responsible for and not “department” they are responsible for.)

Now, to address the portion of his statement: “…to help an auditor be more efficient in his audit of us”. What’s wrong with being efficient as an auditor? Furthermore, what’s wrong with being efficient and organized as a process owner? The more focused you remain on the key deliverables, and the key resources needed to achieve these deliverables, the better chance you have at meeting the needs of your boss (your BOSS boss and your Customer).

Think of a turtle diagram as a point on the global when you go to Google Earth. Before you start navigating north, east, south or west, you first need to make sure you are on the right continent. From there, you can fine-tune and make adjustments. Start your process definition as a very high level. Gather all of the key resources, evaluate your strengths and weaknesses on the turtle and fine-tune from there.

For those of you who prefer a more mathematical explanation, work instructions are to assembly operators as turtle diagrams are to top managers responsible for the performance of a certain business process. Without identifying key outputs – critical to internal and customer satisfaction – it becomes difficult to align all of your tactical resources (man, machine, method, metrics, measurement systems, etc.) in order to achieve your strategic-level goals.

I encourage each organization that uses or considers using turtle diagrams to step back and evaluate the intent of this tool. Like any tool, turtle diagrams are only valuable if used as intended.

Turtle Diagrams Instructions for Creating a Turtle Diagram A “Turtle Diagram” is a quality tool used to visually display process characteristics such as inputs, outputs (expectations), criteria (metrics) and other high-level information to assist in the effective execution and improvement of key business processes. While there is no requirement per ISO 9001 or TS 16949 to create or manage turtle diagrams, I have worked with organizations who use turtle diagrams … Read More

via Concentric Management Systems, Inc.

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