Made by:-Parvesh Mittal

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

Process Chart SymbolsSymbols 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

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

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

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.

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 areaQueue time:- This is the time spent waiting prior to the processing, inspection, and move activitiesExample:- • An operator waiting to get a tool in the stores• Worked pieces stocked near the machine before the next operation

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

VAA & NVA

• Value added activityProviding 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 activityNo 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.

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

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.

Assembly Flow Diagram

1 3

A1 A5

5

A4

62 4

I1 I4 I5I3A3A2 I2

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.

Process Flow Chart

What you think it

is…

What it actually is…

What you would like

it be…

Required Assembly Tasks

Findings

Elements Present method

Steps Time allotted

Operation & transportation

10 37 min.

Inspection 4 16 min.

Total 14 53min.

Value Added Time:

{Operation time/Total Time}

= 37/53 69.81%

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.

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.

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.

Proposed Method

FindingsElements Proposed method

Steps Time allotted

Operation & transportation

10 37 min.

Inspection 2 6 min.

Total 14 43min.

Advantage• Time Saving• Increased Production• High QualityDisadvantage• High Skilled Labor• New Technology

Summary

Elements Present method Proposed method Difference

Steps Time allotted

Steps Time allotted

Steps Time allotted

Operation & transportation

10 37 min. 10 37 min. 0 2 min.

Inspection 4 16 min. 2 6 min. 2 10 min.

Total 14 53min. 14 43min. 7 10 min.

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

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

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.

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.

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.

• 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)…