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7 QC Tools: Process Flow Chart (Video Tutorial)

What is a Process Flow Chart?

  • Process flow chart is the Pictorial presentation of the actual process
  • It is a Chart showcasing the flow of the product or service, in an actual process
  • Standard symbols showcase the different activities of the process connecting by means of arrows on a process flow chart

What are the standard symbols using which one can design a Process Flow Chart?

  • ‘Rounded Rectangle’ uses to showcase the Start and End point of the process
  • ‘Rectangle’ uses to showcase an operation or an activity on the product or service
  • ‘Diamond’ uses to showcase a decision or a condition like accept or reject the product
  • ‘D’ like shape uses to showcase the delay in the process, when the product or service has to wait unnecessarily for its next stage of operation
  • ‘Inverted triangle’ uses to showcase the storage area in the process

Why does the Process Flow Chart use as a qc tool?

  • Bird’s eye view of the actual process
  • Gives an idea, how do the inputs like; raw material, data, or information converting into an output in form of a product or a service
  • Helps in improving the work efficiency of the process
  • Helps in reducing the cycle time of the process
  • Helps in auditing the whole process and tracking the trouble spots
  • Helps in providing, training to new comers to work on the process
  • Helps in identifying the value added and non-value added activities in the process

What are the Value added and Non-Value Added Activities?

  • Value Added Activities:  Activities that make a physical change or added value to the product like; Packing, Sealing, Labelling, etc.
  • Non-Value Added Activities: Activities that make no physical change or added no value to the product like accounting, inspection, counting etc. These activities increase the cycle time of the process hence required as minimum as possible to improve the process efficiency by reducing the cycle time

Working Example

  1. Look at the quality inspection process, the process starts with 100% inspection
  2. Ok parts accepted and send for packing, and defective parts rejected and send to scarp house
  3. After packing, boxes collect for final inspection,
  4. At final inspection, if Acceptance Quality Level is  found OK then the lot is forwarded to ware house, and if AQL is not found OK, then the lot sends for resorting,
  5. At resorting, after 100% inspection of the lot received, Ok parts send for packing again and defective parts send to scrap house
  6. From ware house, boxes send for pre-dispatch inspection, if PDI is not found OK, then Boxes send back to ware house for correction, and If PDI is found Ok then Boxes move to loading, and the Inspection process completes here
  7. This way the process flow chart gives the Bird’s eye view of the whole process and helps in auditing the process, you can remove the unnecessary activities if you think it will improve the process efficiency and reduce the cycle time of the process

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