2-1 Define Process The Quality Improvement Model Use SPC to Maintain Current Process Collect & Interpret Data Select Measures Define Process Is Process Capable ? Improve Process Capability Is Process Stable ? Investigate & Fix Special Causes No Yes No Yes Define Process Purpose: Communicate to an individual or team a clear understanding of the process under study. Establish improved and consistent process operations.

2-2 Define Process Process Components Suppliers Inputs Processes Outputs Customers l A process is any activity that converts l All processes involve Suppliers, Inputs, Outputs, and Customers

2-3 Define Process Defining Processes l Communicate to an individual or a team a clear understanding of the process under study. l Standardize process operations. l Identify and list Suppliers, Inputs, Outputs, and Customers. l Develop flow chart of the process steps. l Assure a common understanding of related procedures. l Verify practice vs. procedure. Why How

2-4 Define Process Process Standardization STANDARDIZATION is everyone following the procedures the same way. “It is neither possible nor necessary to standardize all the operations. However, crucial elements...should be measurable and standardized.” —Misaaki Imai KAIZEN l Are not the optimum perfection. l Are not necessarily the current best known methods. l Are the agreed-upon methods. These Procedures:

2-5 Define Process A Graphical display of the steps in a process. Purchasing Process Standard Symbols Process Steps Decisions Beginning or End Points, or Connectors between pages Manufacturing Submits Purchase Order Purchasing Contacts Vendors for Pricing Vendor Submits Bids Vendor Delivers Goods Manufacturing Inspects Goods Purchasing Pays Vendor Can Vendor Meet Schedule? No Yes End Discuss Quality vs. Price and Select Vendor Process Flow Charts

2-6 Define Process Pumping Filtration Extrusion String Up Quench Cutting Outputs Chip weight Chip viscosity Chip defects Gels Dirt Shutdown/rate Process Mapping

2-7 Define Process l What is the tool?  Graphical illustration of the process l What will the tool identify?  All value-added and non-value- added process steps  Input variables (X’s)  Output variables (Y’s)  Data collection points l When do you apply process mapping?  Always Detailed Process Maps

2-8 Define Process 1. Identify the process, its external inputs and customer outputs 2. Identify all steps in the process graphically 3. List output variables at each step 4. List input variables and classify process inputs as controlled or uncontrolled 5. Add process specifications for input variables Process Mapping Steps

2-9 Define Process Step 1: Identify the Process and Inputs/Outputs l We need to get a 50,000 ft. view of the process first  First identify the process in simple terms  Secondly we identify external inputs oIncoming information oRaw materials oPersonnel oEnergy requirements  Finally we identify the customer requirements (outputs) oIdentify the attributes of a correctly functioning product or service

2-10 Define Process Manufacturing Fluid Bed Dryer Rate Temperature Air Flow Residence Time Appearance (Color) Physical Chem Properties Cycle Time (plugging) Zone 3 Temp InputsOutputs Order Entry Phone FAX Price Availability Confirmation of Order Promise Date Order number InputsOutputs Non- Manufacturing Step 1: Examples

2-11 Define Process l Include all value-added and non value-added steps  Process steps, inspection/test, rework, scrap points Manufacturing Answer Phone Greet customer Determine parts needed Identify need date Identify ship to address Identify price Identify shipment method Internal Information Get internal P/N Determine terms Identify lead time Complete order worksheet Order Entry Input information Print order confirmation Determine ship date Review order Order Confirmation FAX confirmation to customer Verify manufacturing receipt of order Non-Manufacturing Mixing Water and Metals Preparation Extrusion Extrude through die Dryer Calciner NADM Solution Preparation Impregnation Metals addition Fluid Bed Dryer Final preparation / appearance issues Material drying, surface area issues Step 2: Identify All Steps in the Process

2-12 Define Process l Include both process and product output variablesManufacturing Outputs TV of Mix - Quality Check around extrusion Surface Area Pore Volume Appearance pH Temp Specific Gravity Clarity Appearance (Color, Wetness) Appearance (Color) Physical Chemical Properties Cycle Time (plugging) Zone 3 Temp Mixing Water and Metals Preparation Extrusion Extrude through die Dryer Calciner Material drying, surface area issues NADM Solution Preparation Impregnation Metals addition Fluid Bed Dryer Final preparation / appearance issues Step 3: List Key Output Variables

2-13 Define Process l Include both process and product output variables Prompt answer Live body Part number Availability Need date Customer number Order worksheet Pricing Non-Manufacturing Outputs Answer Phone Greet customer Determine P/N Identify need date Identify ship to address Identify ship method Internal Information Get internal P/N Determine terms Identify lead time Complete order worksheet Outputs Order in computer All line items complete Correct info Promise date Order number Printed confirmation Order confirmation to customer Order to production Order Entry Input information Print order confirmation Determine ship date Review order Order Confirmation FAX confirmation to customer Verify manufacturing receipt of order Step 3: List Key Output Variables

2-14 Define Process l List all key input variables and classify them as  Controlled inputs  Uncontrolled inputs Controlled Inputs Controlled Inputs: Input variables that can be changed to see the effect on output variables Sometimes called “knob” variables Uncontrolled Inputs Uncontrolled Inputs: Input variables that impact the output variables but are difficult or impossible to control (may also be controllable, just not under control currently) Example: Environmental variables such as humidity Critical Inputs Critical Inputs: Input variables that have been statistically shown to have a major impact on the variability of the output variables Step 4: List and Classify Key Input Variables

2-15 Define Process Manufacturing Outputs TV of Mix - Quality Check around extrusion Surface Area Pore Volume Appearance pH Temp Specific Gravity Clarity Appearance (Color, Wetness) Appearance (Color) Physical Chemical Properties Cycle Time (plugging) Zone 3 Temp Mixing Water and Metals Preparation Extrusion Extrude through die Dryer Calciner Material drying, surface area issues NADM Solution Preparation Impregnation Metals addition Fluid Bed Dryer Final preparation / appearance issues Total RateC Mixer SpeedC Al2O3 QualU Rec CompU Ext RateC Die WearU Ext RPMsC Die ChangeU TemperatureC Rot speedC DraftC Feed RateC Drying airU Inputs Types Nitric AcidC H2O2C WaterC ADMC Hold TimeU AgitationC Phos AcidC Nozzle TypeC Spray TimeC WaterC MolyC NickelC BaseC TemperatureC RateC Air FlowC Res TimeC Process Mapping Examples

2-16 Define Process Non-Manufacturing Outputs Answer Phone Greet customer Determine P/N Identify need date Identify ship to address Identify ship method Internal Information Get internal P/N Determine terms Identify lead time Complete order worksheet Order Entry Input information Print order confirmation Determine ship date Review order Order Confirmation FAX confirmation to customer Verify manufacturing receipt of order Inputs Type Order worksheet Computer entry screens Lead time information from mfg Shipment method Printed confirmation sheet Production schedule Customer contact info Production contact info Confirmation procedure UCUCUCUC CUCCCCUCCC Inputs Type Information from customer Greeting script Answering procedure Telephone system Cross reference for P/N’s Order information Plant loading information Order worksheet form Pricing algorithm CCCUCCCU CUUCCCUUCC Prompt answer Live body Part number Availability Need date Customer number Order worksheet Pricing Outputs Order in computer All line items complete Correct info Promise date Order number Printed confirmation Order confirmation to customer Order to production Process Mapping Examples

2-17 Define Process l For input variables identified as Controlled and Critical Inputs, we can add the operational specifications and targets for these variables l This information is the beginnings of the Control Plan! Step 5: Add Specifications for Inputs

2-18 Define Process A/ B Degassifier C/D Degassifier DI H 2 O A Cation B Cation C Cation D Cation A Anion B Anion C Anion D Anion Filter H 2 O Example: Building 326 DI Process Flow Chart

2-19 Define Process Big Block Process Building 326 DI Plant External Input Customer Output Filter Water Turbidity Total Hardness Sodium Alkalinity pH Temperature Flow Pressure Colloidal Silica DI Water pH Silica Sodium Conductivity Flow Example Continued…

2-20 Define Process Building 326 DI Process Steps Cation ExchangeDegassifierAnion Exchange Dissolved Ion removal: Calcium Magnesium Sodium CO 2 Removal Removal of: Sulfuric Acid Hydrochloric Acid Carbonic Acid Silicic Acid Filter Water Anion Regeneration Resin Renewal Cation Regeneration DI H 2 O Storage Resin Renewal Example Continued…

2-21 Define Process Bldg. 326 DI Process Map Outputs Cation Water pH Sodium Conductivity Flow Temperature Pressure Turbidity Total hardness Alkalinity Colloidal silica Cation (Production) Ion Removal Filter Water Turbidity C Hardness U Sodium U Alkalinity U pH U Temperature C Flow U Pressure C Colloidal Silica U Inputs Types Resin Type C Level C Condition C Mechanical Condition Valves C Laterals C Screens C Witch’s Hat C DCS C Instrument Calibration C Operator input/interface C Degassifier Level C Example Continued…

2-22 Define Process Bldg. 326 DI Process Map Outputs Regeneration Water Run Length Acid Concentration Regeneration Time Cation (Regeneration) Resin Restoration Acid Quality C Flow C Concentration C Backwash Flow C Acid Displacement Flow C Time C Dilution Water Temperature C Flow C Pressure C Resin Type C Level C Condition C Inputs Types Mechanical Condition Valves C Laterals C Screens C Witch’s Hat C DCS C Instrument Calibration C Operator input/interface C Example Continued…

2-23 Define Process Bldg. 326 DI Process Map Outputs DI Water pH Sodium Silica Conductivity Flow Anion (Production) Ion Removal Degassifier Water Turbidity C Hardness U Sodium U Alkalinity U pH U Temperature C Flow U Pressure C Colloidal Silica U CO 2 C Inputs Types Resin Type C Level C Condition C Mechanical Condition Valves C Laterals C Screens C Witch’s Hat C DCS C Instrument Calibration C Operator input/interface C Example Continued…

2-24 Define Process Bldg. 326 DI Process Map Outputs Regeneration Water Run Length Caustic Concentration Regeneration Time Anion (Regeneration) Resin Restoration Caustic Quality C Flow C Concentration C Backwash Flow C Conductivity C Displacement Flow C Time C Dilution Water Temperature C Flow C Pressure C Resin Type C Level C Condition C Inputs Types Mechanical Condition Valves C Laterals C Screens C Witch’s Hat C DCS C Instrument Calibration C Operator input/interface C Example Continued

2-25 Define Process Bldg. 326 DI Process Map Outputs DI Water Flow to Primester Flow to Blended H 2 O Tank Control of Flow through Anions & Cations DI Water Storage Tank Inputs Types DI Water pH C Sodium C Silica C Conductivity C Flow C Example Continued

2-26 Define Process Bldg. 326 DI Process Map Outputs Degassified Cation Water CO 2 Degassifier CO 2 Removal Cation Water pH U Sodium C Conductivity C Flow C Temperature C Pressure C Turbidity C Total Hardness U Alkalinity U Colloidal Silica U CO 2 U Mechanical Condition Blowers & Filters C Level Control C Internal Baffles C Pumps C Anion Flow C Operating Level C DCS Control # of Pumps Running C Water Level C Blower C Inputs Types Example Continued…

2-27 Define Process Using Process Maps to Evaluate Processes l Understand customer/supplier relationships l Discover unnecessary steps l Achieve agreement on process l Everyone understands their role l Provides inputs to Cause and Effects Matrix l Provides inputs to Control Plan Summary l Provides inputs to Capability Summary Process Map Master.XLS l Excel template: Process Map Master.XLS

2-28 Define Process The Catapult Cup Height Peg Height Hook Height Stop Angle Release Angle

2-29 Define Process The Catapult Process The Catapult process involves using a Catapult to hurl an object to a desired location. Some natural questions about the process are: l Who is the customer? l What does the customer want? l How should the Catapult be operated? l How do I know if I’m meeting customer needs?

2-30 Define Process Catapult 1.)Your Catapult Team should complete pages 1 through 4 of the blue “Catapult Process” handout. Limit yourselves to 30 minutes for this exercise. 2) Be ready to present your work. Note: Do Measure module first. Then do catapult for Define and Measure.