1. Order procurement Input: customer need Sales: identifies customer need
Promotes products &/or R&D capability
Secures customer interest
Receive request for business
Existing product? N
Go to R&D routine Y
New customer? Y
Product mgr/sales rep ”qualifies” customer N
Approved? N
END Y
Quote required?
Proceed with ordering process Y
Product mgr/sales rep/ sales asst prepare quote
Sales rep/designate forwards copy to customer; CS files copies in customer file and in quotation binder
Existing quote in binder?
CS revises Special Pricing Form
CS circulates new SPF: accounting, CS team leader, CSR Y N
Prepare Special Pricing Form
Accounting & CSR remove old SPF from file & shred
Quoted at list price?
Approved by product manager N
CS transfers old SPF to “Expired SPF” binder Y
Approved by sales rep
Proceed with
ordering process
Proceed with
ordering process

2. Order procurement to processing schedule approval
Order placed with CS
Order entered into inventory
& onto Daily Order Summary Sheet
Production clerk reviews order summary (periodically through the day)
Enough product in stock? N
Production clerk opens work order Y
Product automatically deducted from inventory
Three separate MRPs run:
Prod. Clerk, packaging, purchasing
CS prints shipping papers for the order
Enough materials? N
Raw materials ordered/ missing PF items scheduled/ labels prepared
CS generates booking report (daily) Y
CS adjusts ship date with customer (if necessary) & new date added to packing slip
Shipping papers batched with booking report
Production clerk creates processing schedule for following week
If customer changes ship date, date changed on order form and on PO
CS audits orders
Schedule forwarded to plant chemist for approval
Controller audits orders N
OK? Y
CS files shipping papers by ship date
Schedule circulated (distribution list on form)
Go to Shipping routine
Go to processing routine

3. Processing schedule approval to processing testing
Processing schedule circulated as per distribution list
QA issues batch sheets for quantities required prior to start of scheduled week
Supervision required? Y
QA or R&D staff must be present during processing N
Processor fills out temperature & humidity log at shift start
Batch sheets distributed to processors
Processor reviews batchsheet and fills out start-up checklist (where applicable)
Obtains raw materials as listed by item code on batchsheet
Records lot number and weights (gross/tare/net) of each container on batchsheet (“raw materials” section)
Prepares batch as per batchsheet instructions
Records all procedural steps, and observations every 30 minutes (or as specified)
Problems or errors with the batch? Y
Inform Supervisor N
Processor tests batch according to batchsheet instructions
Records all test results on processing summary sheet
Continued…

4. Processing testing to processing approvals
From previous…
Test results within spec? N
Places batch temporarily “on hold”; contacts processing supervisor and QA Y
In-process adjustments applicable? N
Batch rejected and closed into WH07 Y
NCP unloaded from mixer; batch and product ID applied to all containers
Makes in-process adjustments, retests batch
QA applies “HOLD” labels to all containers (including problem, disposition, CAR#) Y
Processor packages batch according to batchsheet instructions
Batch conforms? N
Material transferred to WH 07
Obtains retain sample from the batch
Batchsheet closed and returned to QA lab
Examines packaged containers and ensures all appropriate labels are applied
Production clerk uses material listing to deduct raw materials & close work order
Reviews packaging instructions and signs off beside each container
Go to Control of NCP routine
Confirms conformity of all final test results
Conforms? N
Processing supervisor informed; processor corrects infraction Y
Finished product? N
Processor applies large “Approved” sticker to bottom right-hand corner of PF label Y
Processor signs off on batchsheet & applies green initialed approval dot on product label
Moves containers to “PF Temporary Hold Area”
Moves containers to “Finished Goods Temporary Hold Area”
Places batchsheet in “Approved” file
Continued…

5. Processor corrects labelling
From previous…
QA Packaging performs dock audits on random sample (finished goods only)
All OK? N
Processor corrects labelling Y
QA applies blue dot sticker to finished goods containers, where applicable
PF-material? N Y
Packaging confirms lot #, quantity, and product ID; fills out and signs the Material Transfer Form
Shipping confirms lot #, quantity, and product ID; fills out and signs the Material Transfer Form
Product is stored in WH 04
Product is stored in WH 01
Packaging retains yellow copy of material transfer form & forwards white copy to Production Clerk
Shipping retains yellow copy of material transfer form & forwards white copy to Production Clerk
Production clerk receives material transfer form and approved batchsheet
Transfers out of stock the used raw materials, packaging components and labour used
Confirms quantities of product transferred, using batchsheet and material transfer form
Closes processing work order
Fills in work order number on batchsheet
Batchsheet returned to QA for filing
Files material transfer form with work order