ESCUELA SUPERIOR POLITÉCNICA DE CHIMBORAZO

FACULTAD DE MECÁNICA
INGENIERÍA INDUSTRIAL

PROCESOS DE MEJORA CONTINUA

TRABAJO EN CLASE
Datos
Nombre: Guananga Anthony
Curso: Octavo 1
Fecha: 30-11-2021
 Process Mapping: Processes

Process mapping is a key step in a process improvement project, allowing the inputs, outputs

and individual steps to be visualized, including tasks, resources needed and responsible

parties. As we discussed in the lecture, a process is

 a repeatable, coherent sequence of activities

 performed with a clearly defined input

 to obtain a certain material or immaterial output

 for internal or external customers

Any productive work can be viewed as a process consisting of machinery, manpower,

methods, and measuring schemes, as shown here.

A process receives inputs

 mainly the material, parts, or subassemblies in a production process

 and then processes them in a sequence of operations using machinery, tools

and manpower, and delivers an output.

The environment can sometimes play a significant part in the production activity and can

influence the quality of the output; therefore, it should also be taken into account while

studying the process.

Process Mapping: Process Mapping Example

Every product or service is created or produced by a process; whether it is designing a

product, preparing an invoice, answering a customer complaint, or solving a problem, the

activities can be mapped as a process involving a sequence of steps.

Process mapping can be defined as identifying all the steps in a process the inputs/outputs,

and controls in each step, understanding the responsibilities for each step and mapping the

steps as they occur.

Process mapping is an important first step in an improvement process, as problems are

always the result of a process. In other words, a problem arises in the process and causes a

certain result. Understanding a process fully in order to be able to control and improve it is

the key precept leading to the success of quality improvement programs (such as Six-Sigma.).

For example, here is a simple process for washing clothes. There are 3 steps:

 Soak clothes in water

 Apply detergent

 Wash and rinse the clothes

Process Mapping: Making Blue Jeans
Please read the following text on how to make blue jeans. You will then be asked to
map the process.

Blue Jeans Fabrication Process

 Material collection: Cotton, Dye (synthetic Indigo)

 Preparing Yarn: Incoming cotton is gone through the process of

carding. The threads are made stronger by twisting and
stretching.

 Dyeing: Balls of yarns are dipped in indigo mixture several times.

The dyed yarn is then coated with sizing to make threads stronger
and stiffer.

 Weaving: Yarn is woven on large mechanical looms. Cloth is brushed

to remove loose threads and lint. The denim is then sanforized.

 Making Blue Jeans: This is the final step. Jeans are given design using
patterns cut from heavy paper or cardboard. Sewing is done in an
assembly line fashion. The completed pair of blue jeans is then
pressed.

Below you can see the main process steps for making the blue jeans, as described:
Making the blue Jeans, Dying, Materials, Weaving and Process.
Process Mapping: Quiz

In Quality Management, it is often required to have a process for returning faulty

goods to the supplier. Below we have a process flow for a Return Material Authorisation

(RMA), which is the first step in returning faulty goods.

Given the following process flow for the Return Material Authorisation (RMA), please

answer the following questions:

A Return Material Authorisation (RMA) is
requested by customer who wants to
return faulty or damaged product to Customer
company. (Questions 1 &2) Requests
RMA
Question 3

NO
RMA NO
ill customer Is
request product
pay repair
declined within
costs?
warranty?

Yes Yes
Give RMA Alto
customer Question 4

Customer returns
product

Receive product

Question 6
Test Product

Is cost of Ye
repair s Can product
Repair Product greater than be
cost of repaired?
replacement
?
Return
repaired Ye
product to s
customer
Send
replacemen
t product to
customer Question 5
Multiple Choice

1. What is an RMA?
a process for repairing a product
a process for returning a damaged product for repair
a process for requesting to return a faulty or damaged product

2. Who requests an RMA?

the company who produces the parts

the customer
the repair division

3. When is an RMA request declined?

when the part is not within warranty and the customer will not pay
when the part is within warranty
when the part is not within warranty and the customer will pay

4. What happens before the customer returns the goods?

the customer must pay for the repair

the product must be tested
an RMA # is issued

5. What happens if the product cannot be repaired?

a replacement product is sent to the customer

the RMA request is declined
the repaired product is sent to the customer
6. If the return goods are repairable, what is the decision that has to be
taken?

if the customer will pay the repairs

if the cost of the repair is more than the cost of replacement
if the RMA should be declined