Javier Garcia - Verdugo Sanchez - Six Sigma Training - W4 Statistical Tolerance Analysis
Javier Garcia - Verdugo Sanchez - Six Sigma Training - W1 Process Maps
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Transcript of Javier Garcia - Verdugo Sanchez - Six Sigma Training - W1 Process Maps
Graphical Process Presentation
Process Maps Week 1
Knorr-Bremse Group
p
Content
• Different techniques for process mappingDifferent techniques for process mapping
• The role of process maps in the DMAIC p pcycle
• Use of top-level maps and detailed wall diagrams
• Examples of the different techniques
• Practical use of the tool
Knorr-Bremse Group 04 BB W1Process Maps, 04, D. Szemkus/H. Winkler Page 2/36
Six Sigma & the DMAIC Cycle
ControlMaintain
DefineMaintain
ImprovementsSPC
Control Plans
Project charter (SMART)
Business Score CardQFD VOC
D Documentation QFD + VOC
Strategic GoalsProject strategy
C M
MeasureB li A l iImprove
AIBaseline Analysis
Process MapC + E MatrixAnalyze
ImproveAdjustment to the
OptimumFMEA
Measurement SystemProcess Capability
Definition of critical InputsFMEA
S
FMEAStatistical Tests
SimulationTolerancing Statistical Tests
Multi-Vari StudiesRegression
Tolerancing
Knorr-Bremse Group 04 BB W1Process Maps, 04, D. Szemkus/H. Winkler Page 3/36
S I P ODefinition of a Process
Suppliert
CustomerRequirements Requirements
S I P O C
PROCESS• extern• intern
• extern• internInputs Outputs
Measurement
• A series of activities that transforms a set of inputs, into a specific set of outputs. Workforce, instructions (SOP) and equipment are involved in these activities and required forequipment are involved in these activities and required for information flow and material treatment.
• A process can be analyzed with respect to:Cost– Cost
– Cycle time– Defects
Knorr-Bremse Group 04 BB W1Process Maps, 04, D. Szemkus/H. Winkler Page 4/36
The Periphery of Processes
S I P O C
SupplierSupplier
Input / Requirements / Influence Factors
Process
O tp tOutput / Result / Customer Requirements
Customer
Processes are not islandsKnorr-Bremse Group 04 BB W1Process Maps, 04, D. Szemkus/H. Winkler Page 5/36
Processes are not islands
Diagram Techniques
G hValue Chain
GrowthMarketing
SIPOCDetailed
SIPOCDefects/Variation
Top Level Functional
L d ti
Complex Flows
Effi i /LLead time Efficiency/Lean
The content of this module
F h t t ifi di
The content of this module
Knorr-Bremse Group 04 BB W1Process Maps, 04, D. Szemkus/H. Winkler Page 6/36
For each strategy a specific diagram…
Diagram Techniques
Top level diagram:
Functional diagram:
PA
SS
EN
GE
R (
PA
X)
EN
T
CHECKBAG?
CHECKBAG?
NO
FLYINGFLYING
YES
WRITE UPBAG TAG
WRITE UPBAG TAG
ATTACH
PAXARRIVES @
TICKET COUNTER
PAXARRIVES @
TICKET COUNTER
PAXARRIVES @
DEPART.GATE
PAXARRIVES @
DEPART.GATE
PAXARRIVES @
DESTINATION
PAXARRIVES @
DESTINATION
PAXDEPARTS AIRPORT
PAXDEPARTS AIRPORT
Detailed wall diagram:
TIC
KE
T A
GE
BA
GG
AG
E H
AN
DL
ER
@ D
EP
AR
TU
RE
AIR
PO
RT
ATTACH TAG TO BAG
ATTACH TAG TO BAG
GIVE BAG TAG STUB
TO PAX
GIVE BAG TAG STUB
TO PAXPUT BAG ONCONVEYOR
PUT BAG ONCONVEYOR
SORT BAGS BY FLIGHT NO.
SORT BAGS BY FLIGHT NO.
PLACE BAGS PLACE BAGS
ON CART
DRIVE CART TOPROPER PLANE
DRIVE CART TOPROPER PLANE
LOAD LUGGAGELOAD LUGGAGE
ON PLANE FLYINGFLYING
BAG & PAX
MATCH?
BAG & PAX
MATCH?BAG
ARRIVES @NEXT
BAGARRIVES @
NEXTBAG ON
A
BAG ONA
AIRPLANE
YESNO
FILECLAIM
FILECLAIM
@B
AG
GA
GE
HA
ND
LE
R@
AR
RIV
AL
AIR
PO
RT
ON CARTON CART
ON PLANEON PLANE FLYING
SORTLUGGAGE
IN HOLD OFAIRPLANE
SORTLUGGAGE
IN HOLD OFAIRPLANE
PLACE ON PROPER CART FOR CONNECTING FLIGHT
CONTINUING FLIGHT SEND TO TERMINAL
TERMINATION FLT.
NEXTSTOP
STOPAIRPLANEAIRPLANE
CONNECTING FLIGHT
Pictures / graphics tells more than …
Knorr-Bremse Group 04 BB W1Process Maps, 04, D. Szemkus/H. Winkler Page 7/36
g p
The Basis for the Next Steps
Process Map C & E Matrix•SPC•Solder paste height •Set up control data •Solder quality•SPC•Solder paste height •Set up control data •Solder quality
1 2 3 4 5 6 7 8 9 10 11
Process Step Process Inputs Hea
vies
in
Pro
duct
Ligh
ts in
P
rodu
ctM
oist
ure
in
Pro
duct
Aci
dity
in
Pro
duct
Low
Cap
acity
F
rom
Uni
tE
xces
sive
D
ownt
ime
Mat
eria
l Lo
sses
Cor
rosi
on o
f E
quip
men
tP
oor
Rea
ctor
P
erfo
rman
ce
Total
139 Day Tanks Analysis 10 10 9 9 3359 Reactor Cat./HF Ratio 5 8 7 157
Reflow paste-print
SMD-Placement
Reflow-Soldering
SPC-check
M Circuit boardN LP-marksM Solder paste
M ComponentsC Placement programC BE post supply
C Solder profile ProgramS Auxiliary materialN Maintenance condition
N Control loop-information
I Control film
Solder paste height Set up control data Solder quality
Reflow paste-print
SMD-Placement
Reflow-Soldering
SPC-check
M Circuit boardN LP-marksM Solder paste
M ComponentsC Placement programC BE post supply
C Solder profile ProgramS Auxiliary materialN Maintenance condition
N Control loop-information
I Control film
Solder paste height Set up control data Solder quality
9 Reactor Cat./HF Ratio 5 8 7 1577 Reactor Rxr Temperature 6 5 4 7 14973 Lights Removal Condenser Leak 4 8 2 4 1 14874 Lights Removal Reboiler Leak 4 8 2 4 1 148131 Purification Low Stages 8 8 144144 Final Storage Containers 3 2 6 6 140100 Neutralization pH Value 6 6 3 13816 Catalyst Stripper Pluggage 3 6 5 3 137111 Drying Decomposition 2 6 3 2 2 13439 Drier Water Carryover 4 6 5 1 13234 Drier MolecularSieve 3 3 2 7 2 125THT- FinalWave-
pI Work instructionN ModelN Temperature
p pp yI Work instructionsN PneumaticN Maintenance condition
N Oven contamination I Control instructions
•Placement quality •Solder wave parameter •Go / no go•Defect number•Defect sheet•DiagnosisTHT- FinalWave-
pI Work instructionN ModelN Temperature
p pp yI Work instructionsN PneumaticN Maintenance condition
N Oven contamination I Control instructions
•Placement quality •Solder wave parameter •Go / no go•Defect number•Defect sheet•Diagnosis 34 Drier Molecular Sieve 3 3 2 7 2 125
Capability of process and
THTPlacement
Final inspection
WaveSoldering
M ComponentsI Roy.- ProgramI Placement instructionN Training
I Solder parameterM Auxiliary materialM Solder maskN Maintenance condition
I Inspection programN AdapterN Net work
•DiagnosisTHTPlacement
Final inspection
WaveSoldering
M ComponentsI Roy.- ProgramI Placement instructionN Training
I Solder parameterM Auxiliary materialM Solder maskN Maintenance condition
I Inspection programN AdapterN Net work
•Diagnosis
USLLSL
FMEA
measurement system
Process Step/Part Number
Potential Failure Mode Potential Failure EffectsSEV
Potential CausesOCC
Current ControlsDET
RPNActions
RecommendedResp.
COATING & IMAGING
DIRTY PHOTOMASK MICROCRACKING, DELAMINATION, STREAKS 8
LOW FREQUENCY OF CLEANING
8
SOP, VISUAL INSPECTION
7 448
INCREASE FREQUENCY TO ONCE EVERY 20 PANELS
MG
33323130292827
IMPROVE CLEANING METHOD
PF
PURCHASE OFF-LINE CLEANING SYSTEM
MG
TEST ON-LINE MASK REPLACEMENT
PF
Knorr-Bremse Group 04 BB W1Process Maps, 04, D. Szemkus/H. Winkler Page 8/36
Benefits of Process Maps
• Basis for the Cause & Effect matrix
• Basis for the FMEABasis for the FMEA
• Inputs for the capability summary
• Inputs for Multivari Studies• Inputs for Multivari-Studies
• A living document
– Process description (ISO …)
– Basis for “on the job training”
Knorr-Bremse Group 04 BB W1Process Maps, 04, D. Szemkus/H. Winkler Page 9/36
The Process Presentation
There are several possibilities for a process map…
How we think it is... How we wish it is...How it is in reality...
Knorr-Bremse Group 04 BB W1Process Maps, 04, D. Szemkus/H. Winkler Page 10/36
Top Level Diagram
The procedure for process map creationThe procedure for process map creation
Name of the process
Split in detailed stepsCustomer
Split in detailed stepsInputs
Outputs
• _______ • _______• _______• _______
Important partial steps
• _______• _______• _______
• _______• _______• _______
• _______• _______• _______
• _______• _______• _______
Knorr-Bremse Group 04 BB W1Process Maps, 04, D. Szemkus/H. Winkler Page 11/36
Top Level Diagram
An example:An example:
Passenger arrives at
check-in counter
Tag bag atcheck-in counter
Transport bag to baggage claim area
Passenger leavesairport
Transport bag to plane
Transfer bagto connecting
plane
• Check final destination
• Place bag on cart bound for d i d fli h
• Unload bags not designated for flight
i i
Porter:
Pl b i• Prepare tag
• Attach tag to bag
S l b i
designated flight
• Wait until cart isfull, or until 15 minute before
h d l d fli h
continuation on cart
• Drive cart to terminal
• Separate bagsdi
• Place bags in designatedbaggage claimscarousel
P• Staple bag receipt to ticket
• Place bag on moving belt
scheduled flight
• Drive cart to plane
• Load bags to plane
according toconnecting flights
• Load bags oncarts in terminald i d f
Passenger:
• Check tag against receipt
If b i f ddesignated forconnecting flight, or transport to baggage claim area
• If bags is not found, file claim
Knorr-Bremse Group 04 BB W1Process Maps, 04, D. Szemkus/H. Winkler Page 12/36
Detailed Process Mapping
• What is the purpose of the tool • When should a process map p p– Graphical description of the
process
p pbe used?– Always
• What will the tool identify?– All process inputs (X)
• What are the outputs of a process map?– All process inputs (X)
– All process outputs (Y)– Data collection points
process map?– Identification of systems
which need a measurement system evaluation
p– The first relationships, which
will be investigated by the FMEA
system evaluation– Identification of outputs for
capability studiesFMEA– Shows all value adding and
non value adding process
p y– Identification of gaps in the
control planO t iti f li i tisteps – Opportunities for elimination of process steps
Knorr-Bremse Group 04 BB W1Process Maps, 04, D. Szemkus/H. Winkler Page 13/36
Process Description
• The process map shall describe:
– Main activities / tasks
– Sub processesSub processes
– Process boundaries
Inputs (X)– Inputs (X)
– Outputs (Y)
• Has to be checked and updated frequently
y f x x xk= ( , ,..., )1 2y f x x xk( , ,..., )1 2
Knorr-Bremse Group 04 BB W1Process Maps, 04, D. Szemkus/H. Winkler Page 14/36
Preparation for Process Mapping
• Selection of team members:– Planning / manufacturing engineers– Operators
Supervisor– Supervisor– Maintenance staff
• Necessary inputs:– Brainstorming
O ti l– Operating manuals– Technical specifications– Experience of the operatorsExperience of the operators– 6 Ms
Men, Machine (Equipment), Method (Technique), M t M t i l M th N t (E i t)Measurement, Material, Mother Nature (Environment)
Knorr-Bremse Group 04 BB W1Process Maps, 04, D. Szemkus/H. Winkler Page 15/36
Steps to Create a Process Map
Identification of the process, the inputs (from suppliers) and outputs (from customers), can be
1suppliers) and outputs (from customers), can be external as well internal (partners) suppliers and customers (helpful S.I.P.O.C.)!
Identification of all process steps
P t D i i
2
Process step Decision
Further symbols e.g.: Power point > Auto form > Flow diagrams
Listing of all output variables for each process step
Listing of all input variables for each process step
3
Listing of all input variables for each process step
Characterization of the process inputs in controllable i t i ( t t ll bl ) d i t ti
4inputs, noise (not controllable) and instructions
Knorr-Bremse Group 04 BB W1Process Maps, 04, D. Szemkus/H. Winkler Page 16/36
Step 1:
Identification of the process and the inputs/outputs
• Identification of Inputs– Material (raw materials, parts, etc.)– Information (order, specifications, etc.)
• Identification of the OutputsU th d t d i QFD f th id tifi ti f th– Use the product design - QFD for the identification of the final product specification
WaxInputs Outputs
WaxOxidation
LMWPE WaxAir flow
Acid numberColorAir flow
TemperaturePressure
ColorViscosityDrop testHardness
Knorr-Bremse Group 04 BB W1Process Maps, 04, D. Szemkus/H. Winkler Page 17/36
Hardness
Step 2:
Identification of all process steps
• Include all steps, value adding and non value ddiadding– Activities/Transformations, Inspections/Tests,
Rework ScrapRework, Scrap
Preparation Reactor Oxidation Stabilization Filling
Bring in waxHeat up reactor temp.
Parameter adjustmentFrequent observation of
acid number
Parameter adjustmentslow pressure reduction
Temp. observation
Check nozzle typeParameter adjustment
Consistence observationobservation
Knorr-Bremse Group 04 BB W1Process Maps, 04, D. Szemkus/H. Winkler Page 18/36
Step 3:
Consider process as well product output variables
Listing of all important output variablesConsider process as well product output variables
Outputs•TimeA id b
•TimeA id b
Outputs
Preparation Reactor
Bring in waxHeat up reactor temp.
Stabilization
Parameter adjustmentslow pressure reduction
•Acid number•Viscosity•Reactor temp.•Temp. profile
•Acid number•Color•Viscosity•Reactor temp.•Temp profileTemp. observation •Temp. profile•Gas flow
Oxidation Filling
OutputsOutputs•Time•Acid number•Color
•Oxidation time•Acid number•Color
Parameter adjustmentFrequent observation of
acid number
Check nozzle typeParameter adjustment
Consistence observation
Color•Viscosity•Drop test•Hardness•Granulate optic
Color•Viscosity•Reactor temp.•Temp. profile•Gas flow observation p
Knorr-Bremse Group 04 BB W1Process Maps, 04, D. Szemkus/H. Winkler Page 19/36
Step 4:
Characterization of the important input variablesThe input variables can be characterized as followsThe input variables can be characterized as follows
•Controllable•Noise (not controllable)•Instructions (Standard operating procedures)
Controllable inputs: Changeable inputs which have an effect of the
Instructions (Standard operating procedures)
Controllable inputs: Changeable inputs which have an effect of the outputs (results). Can be adjusted.
Noise inputs: Input variables which have an effect on the outputs (results) but difficult or not possible to control(results), but difficult or not possible to control.
Example: Environment conditions like humidity
Instruction (Standard operating procedures): Qualitative or quantitativeInstruction (Standard operating procedures): Qualitative or quantitative variables, which specifically describe the operation of a process (e.g. parameter adjustments, etc.)
C iti l i t (KPIV) V i bl hi h h t ti ti l i ifi tCritical inputs (KPIV): Variables which have a statistical significant effect on the outputs (results).
Knorr-Bremse Group 04 BB W1Process Maps, 04, D. Szemkus/H. Winkler Page 20/36
Example Process Description:
Add and characterize input variables
Outputs•TimeA id b
•TimeA id b
Outputs•Wax I
C
Inputs InputsMix speed C
Preparation Reactor
Bring in waxHeat up reactor temp.
Stabilization
Parameter adjustmentslow pressure reduction
•Acid number•Viscosity•Reactor temp.•Temp. profile
•Acid number•Color•Viscosity•Reactor temp.•Temp profile
•Feed rate C•Mix speed C•Temp. C•Pressure CAir flow C
•Temp. C•Pressure C•Air flow C•% O2 in air NAi t C Temp. observation •Temp. profile
•Gas flow•Air flow C•% O2 in air N•Viscosity N•Wax temp N
•Air temp. C
Oxidation Filling
OutputsOutputs•Time•Acid number•Color
•Oxidation time•Acid number•Color
Inputs•Given SZ I•Mix speed CT C
Inputs•Line speed C•Line temp. CFl t C
Parameter adjustmentFrequent observation of
acid number
Check nozzle typeParameter adjustment
Consistence observation
Color•Viscosity•Drop test•Hardness•Granulate optic
Color•Viscosity•Reactor temp.•Temp. profile•Gas flow
•Temp. C•Pressure C•Air flow C•% O2 in air N•Air temp N
•Flow rate C•Nozzle type I•Whole size I•Room temp. N•Mix speed C observation p•Air temp. N
•Humidity N•Mix speed C•Tank temp. C
Knorr-Bremse Group 04 BB W1Process Maps, 04, D. Szemkus/H. Winkler Page 21/36
Another Example
The Top Level
Sub-assembly manufacturing
Input Output
g
Order Sub assembly qualityOrderMaterialWork plan
Sub-assembly qualityNumber of defectsProcess time
Adjustment instructionsMachine
Process timeDiagnostic resultsManufacturing cost
Environmental conditionsOperatorD t t k
gNumber of units
Data networkManufacturing capacityProcess engineering
Knorr-Bremse Group 04 BB W1Process Maps, 04, D. Szemkus/H. Winkler Page 22/36
Process engineering
S lit i i l tSubdivision in Single Steps
Input Output
Split in single steps
S b assemblInput OutputSub-assembly manufacturing
Reflow paste print
SMD-Placement
Reflow-Soldering
SPC-Checkpaste-print Placement Soldering Check
THT- Final Wave-Placement InspectionSoldering
Knorr-Bremse Group 04 BB W1Process Maps, 04, D. Szemkus/H. Winkler Page 23/36
Detailed Process Map • Inspection results• Control loop info to
SMD/Screen printor line stop
•SPC•Solder paste height •Set up control data •Solder quality
Reflow paste-print
SMD-Placement
Reflow-Soldering
SPC-check
M Circuit boardN LP-marksM Solder pasteI Work instruction
M ComponentsC Placement programC BE post supplyI Work instructions
C Solder profile ProgramS Auxiliary materialN Maintenance conditionN Oven contamination
N Control loop-information
I Control filmI Control instructionsI Work instruction
N ModelN Temperature
I Work instructionsN PneumaticN Maintenance condition
N Oven contamination I Control instructions
THT- Final Wave-
•Placement quality •Solder wave parameter •Go / no go•Defect number•Defect sheet•Diagnosis
Placement inspectionSoldering
M ComponentsI Roy.- Program
I Solder parameterM Auxiliary material
I Inspection programN AdapterI Roy. Program
I Placement instructionN Training
M Auxiliary materialM Solder maskN Maintenance condition
N AdapterN Net work
Legend of the Inputs: M = Material, C = Controllable, N = Noise, I = Instruction
Knorr-Bremse Group 04 BB W1Process Maps, 04, D. Szemkus/H. Winkler Page 24/36
Legend of the Inputs: M Material, C Controllable, N Noise, I Instruction
Practical Exercise with the Catapult
King Louis has an strong interest to conquer the castle Frankenstein This castle is a strategic important point andFrankenstein. This castle is a strategic important point and gives his enemy King George currently the opportunity to control a part of King Louis kingdom.control a part of King Louis kingdom.
The master carpenter of King Louis has developed a new prototype of weapon a catapult The King wants to usenew prototype of weapon, a catapult. The King wants to use the catapult to take over castle Frankenstein in order to ensure independency and freedom.depe de cy d eedo .
Your assignment is to create a process map for the installation process and the launch process The King willinstallation process and the launch process. The King will specify later where the catapult has to be set up in relation to the castle. The condition may change from day to day, so that y g y y,the shooting distance to the castle will vary as well.
( Time frame: 30 minutes followed by a team presentation)
Knorr-Bremse Group 04 BB W1Process Maps, 04, D. Szemkus/H. Winkler Page 25/36
( Time frame: 30 minutes, followed by a team presentation)
Practical Application
Pizza Service:Pizza Service:
Develop a top level diagram from the order entry up p p g y pto the delivery at the door of the customer. For one of the process steps create a detailed map with inputs and outputs
For your own project:y p j
Start to develop a process map for you own project and use this for the next team meetingand use this for the next team meeting
Knorr-Bremse Group 04 BB W1Process Maps, 04, D. Szemkus/H. Winkler Page 26/36
Summary
• Different techniques for process mapping
Th l f i th DMAIC l• The role of process maps in the DMAIC cycle
• Construction of top-level maps and detailed wall p pdiagrams
• Examples of the different techniques• Examples of the different techniques
• Practical use of the tool
Knorr-Bremse Group 04 BB W1Process Maps, 04, D. Szemkus/H. Winkler Page 27/36
Appendix
and further examples of process maps
Knorr-Bremse Group 04 BB W1Process Maps, 04, D. Szemkus/H. Winkler Page 28/36
Reduction of Cycle Times – Process Analysis
Definition:• A step is value adding if:• A step is value adding if:
– the customer recognizes the value– the product changes, ande p oduc c a ges, a d– when it is done the first time
• A step is waste if:– it needs more than the minimum of equipment, material, parts,
d k ti th t i b l t f lspace and work time that is absolute necessary for value adding.
• A step is needed / necessary if:– it is required due to law, a regulation or a contractq , g– it is required for health, safety and environment or for ethical
reasons
Knorr-Bremse Group 04 BB W1Process Maps, 04, D. Szemkus/H. Winkler Page 29/36
Reduction of Cycle Times – Process Analysis
Calculation of time demand for goal setting
+ Transport between departmentsW i i i
None
+ Waiting time+ Sorting+ Storage+ I tim
e
valueadding
+ Inspection+ Checks+ Admission+ Filingcl
e ti
m
+ Filing+ Corrections / Rework
tal
cyc
+ Writing+ Production+ A l i
Value
Tot
3R l ti X+ Analysis+ Assembly
= Raw cycle time
adding= Goal
3Raw cycle time X
Knorr-Bremse Group 04 BB W1Process Maps, 04, D. Szemkus/H. Winkler Page 30/36
Raw cycle time
Reduction of Cycle Times – Process Analysis
“What is the reason for a break?” – Analysis on the wall chart
Answer the following questions to identify areas where process time can be shortened.
Non value addingWhich activities are not value adding?gWhich activities could be eliminated?Which activities could be combined?Which activities could be replaced by more simple ones?
Long rows: More activities at the same time?Long rows: More activities at the same time?Were are long chains of tasks in the process map?Which key tasks can be started before previous activities are completed?Which key tasks can be started before previous activities are completed?Which activities can be started earlier than currently assumed?
Knorr-Bremse Group 04 BB W1Process Maps, 04, D. Szemkus/H. Winkler Page 31/36
Another Format (Example)KPIVs Process Step KPOVs
Input type Major Step Sub-process Output
SBS noise Evaluate Incoming Materials Material Characteristics:g granular size noise Softening Point
PenetrationCoal Tar noiseOil noiseFill iFiller noiseFire Retardants noiseStandard formula SOP
Material characteristics SOP Formula Preparation Lab blendpSoftening PointViscosityPenetration
Historic data SOP % Coal Tar% Other ingredients% Other ingredients
Prepare Production Batch Sampleprocedure SOP Zero the tank Softening Point
ViscositySOP Clean transfer lines/filters Penetration
Tank temp. process Set tank temperatureFormula SOP Add Coal tarFormula SOP Add oil275-300 RPM Controllable Agitate275 300 RPM Controllable AgitateMotor horsepower ControllableFormula SOP Add SBS1 1/2 hours mix Controllable Add stabilizers1 hour mix Controllable Add fillers
Knorr-Bremse Group 04 BB W1Process Maps, 04, D. Szemkus/H. Winkler Page 32/36
holding time Controllable Transfer to holding tank
Example, Wall Chart
NO
PAXARRIVE
AIRPORT
TICKET AGENT
WRITE UPBAG TAG
ATTACH TAG TO
BAG
TAG STUBTO
PAX
CHECK BAG?
BAG TOCONVEYOR
SORTBAG BY FLIGHT
YES
BAG TAG
NO
YES
LOAD CART
FLIGHT ACTIVITY
ANDARRIVAL
LOADAIRCRAFT
BAGS TOAIRCRAFT
BAGSON
PROPER CART
SORTBAGS IN
AIRCRAFTHOLD
LEAVEON
PLANE?
NO
CART TOBAGGAGE
PAX TO BAGGAGE BAG &
YESHAPPYBAGGAGE
PICK UPBAGGAGE
PICK UP
BAG &PAX
MATCH?
HAPPYCUSTOMER
NO
FILE CLAIM
PAXLEAVE
AIRPORT
Knorr-Bremse Group 04 BB W1Process Maps, 04, D. Szemkus/H. Winkler Page 33/36
Wall Chart with Inputs and Outputs
Bag on ConveyorPax Gets Tag
Tag Attached to BagTag Written UpOutputs (y’s)
...PAXARRIVE
AIRPORT
TICKET AGENT
WRITE UPBAG TAG
ATTACH TAG TO
BAG
TAG STUBTO
PAX
CHECK BAG?
BAG TOCONVEYOR
YES
Ticket AgentTagBagPenFlight NumberP
Ticket AgentTagBag
Ticket AgentTag StubPassengerTip Money
Ticket AgentTagged BagConveyorInputs (x’s)
Passenger
Knorr-Bremse Group 04 BB W1Process Maps, 04, D. Szemkus/H. Winkler Page 34/36
Create a Functional Process Map
• The top level diagram is the foundation
• Select a team
• Team tasks:Team tasks:
– Collection of all process steps (Hint: Post It‘s),
Grouping in accordance to functions– Grouping in accordance to functions,
– What is running parallel or what depends on each other,
– Collection of inputs and outputs for each step,
– What are the min - max times for each step,
– Important: all rework loops have to be included
• After completion a practical check is neededp p
• Get feedback from others involved in the process
Knorr-Bremse Group 04 BB W1Process Maps, 04, D. Szemkus/H. Winkler Page 35/36
Example: Functional Process Map
EN
GE
R (
PA
X)
CHECKBAG?
NO
FLYING
PAXARRIVES @
TICKET
PAXARRIVES @
DEPART.
PAXARRIVES @
DESTINATION
PAXDEPARTS
PA
SS
E
YES
WRITE UP
COUNTERCOUNTER GATEDESTINATIONDESTINATION AIRPORT
TIC
KE
T A
GE
NT
WRITE UPBAG TAG
ATTACH TAG TO BAG
GIVE BAG TAG STUB
FILECLAIM
T
DL
ER
IRP
OR
T
TO PAXPUT BAG ONCONVEYOR
SORT BAGS BY DRIVE CART TO
BA
GG
AG
E H
AN
D@
DE
PA
RT
UR
E A
I SORT BAGS BY FLIGHT NO.
PLACE BAGS ON CART
DRIVE CART TOPROPER PLANE
LOAD LUGGAGEON PLANE
FLYING
BAG & PAX
MATCH?BAG
ARRIVES @NEXT
BAG ONA
AIRPLANE
YESNO
@A
ND
LE
RA
IRP
OR
T
ON CART ON PLANEFLYING
STOPAIRPLANE
BA
GG
AG
E H
A@
AR
RIV
AL
A
SORTLUGGAGE
IN HOLD OFAIRPLANE
PLACE ON PROPER CART FOR CONNECTING FLIGHT
CONTINUING FLIGHT SEND TO TERMINAL
TERMINATION FLT.
CONNECTING FLIGHT
Knorr-Bremse Group 04 BB W1Process Maps, 04, D. Szemkus/H. Winkler Page 36/36