Last updated on Feb 8, 2024
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Choose a purpose and scope
2
Gather information and data
3
Select a flowchart type and symbols
4
Draw your flowchart
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5
Validate and improve your flowchart
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Here’s what else to consider
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A manufacturing process flowchart is a visual representation of the steps, inputs, outputs, and resources involved in producing a product or service. It can help you identify and eliminate waste, optimize efficiency, improve quality, and communicate your processes to others. But how do you create one? What tools should you use? Here are some tips to help you get started.
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- ALI ASGHAR Quality Assurance Manager @ PCI Automotive | Process Improvement, Root Cause Analysis 2
1 Choose a purpose and scope
Before you draw your flowchart, you need to define its purpose and scope. What problem are you trying to solve? What process are you trying to improve? Who are the stakeholders and customers? How detailed do you want your flowchart to be? Answering these questions will help you focus on the most relevant and useful aspects of your process and avoid unnecessary complexity.
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- ALI ASGHAR Quality Assurance Manager @ PCI Automotive | Process Improvement, Root Cause Analysis
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The production flow chart works as a visual tool. It’s a picture that illustrates each step of a process in sequential order and it’s used for defining or analyzing new processes, standardizing or redesigning existing processes and finding ways to improve processes by removing unnecessary steps, bottlenecks, etc.Here is flow chart symbols and and it meaning:1. Oval start or finish of the process2. Arrow direction of the process one step to another.3. Rectangle represents a process4. Diamond is a decision on an activity5. D-shape means delay or wait6. Rectangle that curves up on the bottom right side represents supportive documents required7. Rounded-edged rectangle is sometimes used as the start or finish of a process.
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2 Gather information and data
Next, you need to collect the information and data that will inform your flowchart. You can use various methods, such as interviews, observations, surveys, documents, or measurements, to gather the facts and figures about your process. You should also involve the people who perform or oversee the process, as they can provide valuable insights and feedback. Try to capture the current state of your process, as well as any issues, variations, or opportunities for improvement.
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- ALI ASGHAR Quality Assurance Manager @ PCI Automotive | Process Improvement, Root Cause Analysis
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How we make a production flow chart.1. Identify TasksWe have to know tasks in the production process, everything from start to finish. With this first step and include your production team to help you outline the steps.2. Add Details to the TasksWe make a team members who are responsible for those tasks. we need to identify any variables and events that might deviate the process.3. Check Your WorkIt’s critical that we get these first steps right. Once we've completed, it’s important that stakeholders review it will help us to make sure that what we collected is accurate. 4. Make Your Flow ChartOnce okay from stakeholders, we can begin to draw production flow chart. Use the symbols to map out the production flow chart.
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3 Select a flowchart type and symbols
Now, you need to decide what type of flowchart you want to use and what symbols you want to employ. There are different types of flowcharts, such as basic, swimlane, deployment, or value stream, that can suit different purposes and levels of detail. You should also familiarize yourself with the standard flowchart symbols, such as rectangles, diamonds, circles, and arrows, that represent different elements and actions in your process. You can also use colors, labels, or icons to enhance your flowchart.
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- ALI ASGHAR Quality Assurance Manager @ PCI Automotive | Process Improvement, Root Cause Analysis
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There are two common types of production flow charts, high-level and detailed usually only featuring six to 10 phases or steps and focusing on the major blocks in a process. It’s used mostly to identify improvements.The detailed flow chart as its name suggests goes into greater detail or a micro view of the activities in your master production schedule. These flow charts are at least 15 phases or steps long and often much more.Flow chart symbols and it meaning;1. Oval start or finish of the process2. Arrow direction of the process one step to another.3. Rectangle represents a process4. Diamond is a decision on an activity5. D-shape means delay or wait6. Rectangle that curves up on the bottom right side
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Depending on your industry, there are different flowchart methods. For example, in the chemical processing industry you can use SuperPro to not only develop the flow chart, but you can also execute mass balance equations against a charged system to determine weights, values, cost, run-times, etc. For quick and easy flow charts, I would recommend Visio, and I would use that in conjunction with colored swim lanes. Visio has fairly standardized symbols, and the swim lanes will depict if your process moves through Operations, Quality, Transportation, Shipping, and Receiving, Warehousing, etc.Visio is very easy to learn, and it is visually appealing.
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4 Draw your flowchart
The next step is to draw your flowchart using the information, data, type, and symbols you have chosen. You can use various tools, such as paper and pencil, whiteboard and markers, or software and applications, to create your flowchart. The choice of tool depends on your preference, budget, and availability. However, some advantages of using software or applications are that they can offer more features, flexibility, and collaboration options. You should start with the main steps of your process and then add more details as needed.
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5 Validate and improve your flowchart
The final step is to validate and improve your flowchart. You should review your flowchart with the people who are involved in or affected by the process, and check if it accurately reflects the reality and meets the purpose and scope. You should also test your flowchart by running scenarios, simulations, or experiments, and measure the results. You can then identify and implement any changes or improvements that can enhance your process and flowchart.
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6 Here’s what else to consider
This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?
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