Process Control

for manufacturing
companies

Process flow mapping

Staf Henderieckx
Quality

Definition:
“In manufacturing, a measure of excellence or a state of
being free from defects, deficiencies, and significant
variations, brought about by the strict and consistent
adherence to measurable and verifiable standards to
achieve uniformity of output that satisfies specific
customer or user requirements. ISO 8402-1986
standard defines quality as "the totality of features and
characteristics of a product or service that bears its
ability to satisfy stated or implied needs."
”
Quality (2)

Definition:
“Quality itself has been defined as fundamentally
relational: 'Quality is the ongoing process of building
and sustaining relationships by assessing, anticipating,
and fulfilling stated and implied needs”
Quality (3)

Definition:
“Quality is a customer determination based upon a
customer's actual experience with a product or service,
measured against his or her requirements -stated or
unstated, conscious or merely sensed, technically
operational or entirely subjective- and always
representing a moving target in a competitive market”
Quality (for export)
Quality is right if the basic demands of the EU customer
is met consistently:
• Right product
• Right price
• Right delivery time
• Proper and timely customer communication

If you do this right all the time, your company enjoys a

predictable profit
Influences on quality
Categories of influences
• Machine (production equipment)
• Material (raw materials, sub-assemblies, consumables)
• Method (work floor instructions)
• Man (workers, supervisors, managers, owners)
• Management - Money

“5M” product, price, delivery time, customer

communication.
Influences of quality on cost / competitiveness

Wrong product • higher cost

Wrong price • worse than your
Wrong delivery time competitor
Poor customer communication
You
Competitor

Product cost
break down
Process
Process = deliberate chain of activities, connected by
intermediate inputs and outputs

output
input Activity Activity output (Product)
input

Process’ final output = (export) product

Uncontrolled process = process + unintended disturbing
influences
Controlled process = process + eliminated influences
Examples of activities
Casting, Milling, Machining, Welding, Grinding, …
Assembling
Tool preparation
Inspection
Internal transportation
Intermediate storage
Material testing for certification conformance (required by the
customer)
…
Examples which we do not regard an activity
Out of scope for the purpose of this training course:
Human resources
Account payable / receivable
…
Activity, input, output
Input = physical flow
Activity = transformation on the physical flow
Output = transformed physical flow

Example:
Input = rusty plate (adjective + noun)
Activity = sandblast plate (verb)
Output = sandblasted plate (adjective + noun)
Activity, input, output (2)
Example:
Input = stock bar (noun)
Activity = bend bar (verb)
Output = bent bar (adjective + noun)

Example:
Input = bracket (noun)
Activity = drill bracket (verb)
Output = drilled bracket (adjective + noun)
Process flow
Deliberate chain of activities

Activity 5 Activity 6

Activity 1 Activity 2 Activity 3 Product

Activity 4
Process disturbances
Each activity or input/output may experience disturbing influences

Activity 5 Activity 6

Activity 1 Activity 2 Activity 3 Product

Activity 4 5M !
Process optimization is our goal
A controlled process = process + eliminated influences
Steps to achieve a controlled process:
• Set targets for each activity, its input, its output
• Identify disturbances and determine corrective actions to eliminate them
• Apply the corrective actions (= control !)
• Measure results on each activity, its input, its output
• Continuously optimize in order to achieve the targets predictably and
consistently, so as to achieve:
• Right product
• Right price
• Right delivery time
• Proper and timely customer communication
Initial process flow mapping
Assignment
• Present your pre-course assignment 1
• Present your pre-course assignment 2