Flowchart is one of the three basic documents created by a production plant during pre-launch phase. Two others are Control Plan and PFMEA. Additionally, it is one of the seven basic quality tools.
It is also called a process diagram or process flow diagram.
Flowchart is a general tool that can be customized for many different purposes and can be used to describe different processes such as a manufacturing process or a project plan. It is also a common process analysis tool.
The elements that can be included in a flowchart are the sequence of activities, materials or services entering or leaving the process (inputs and outputs), decisions that must be made, involved people, time spent on each step or process measurements. It shows the various steps of the process in sequential order.
Flowchart – when to apply
In the case of the automotive industry, the answer is very simple, because it is always used together with the Control Plan and PFMEA. During Advanced Product Quality Planning, the first version of the Flowchart is prepared in the first phase of APQP “I. Product Planning and Quality Program Definition”. However, the final version should be created in phase “III. Process Design and Development ”.
Depending on the required level of part submission for approval by the PPAP / PPA / PE customer, this version of the diagram should be considered.
Additionally, it is used to:
- understanding how the process works
- potential improvement process study
- communicating to others how the process is going (including customer representative)
- improving communication between team members involved in the same process
- process documenting during project planning
Flowchart – basic symbols
– process element. The description is presented in a rectangle. Usually only one arrow comes out of it.
– flow direction from one step or decision to another.
– Decision gate based on the question. The question is placed in a diamond. More than one arrow comes out of the diamond, each of which points in the direction in which the process of obtaining an answer to the question is taking. Often the answers are “yes” and “no”.
– Delay or waiting.
– Link to another page or another flowchart. The same symbol on the other side indicates that the flow continues there.
– Input or output.
– manual operation.
An example of above symbols application is shown below.
Diagram 1. An example of the Flowchart practical application.
Additional customer requirements which has to be considered
During Flowchart defining, customers (OEM’s) often require that in operations where a safety characteristic is created, an additional distinction is made with respect to other processes.
In addition, when considering repair or rework operations (see IATF requirement. 8.7.1.4 Control of reworked product and 8.7.1.5. Control of repaired product), a feedback loop should be included in the flowchart showing where the product will be repaired or reworked reverted to the standard production process.
Another element that should be included in the flowchart is information about production processes carried out outside the production plant. The most common of them are: painting, carburizing, galvanizing and hardening.
We must also remember about the Customers Specific Requirements.
You can download an automatic, editable Excel form for free on the Free Quality Tools
Document name: Process Flow Diagram – Excel form
