Manufacturing Flow Charts And Process Maps

Manufacturing organizations face increasing pressure to improve quality while reducing costs and increasing production with fewer resources. Six-Sigma has proved to be an excellent tool for reducing costs and improving productivity and quality. Manufacturing process mapping can show how a wisely used low cost technique increases productivity and improves quality.

In many manufacturing units, involving high volumes, engineers decide on low cost automation. Their main focus is on improving productivity. Improvement in quality is treated as a secondary and not-so-important product of automation. In such situations, if Six Sigma methodology is practiced, the consequent analysis can lead to focused problem solving.

Case experiences reveal that combining manufacturing process mapping and data analysis with simulation is advantageous. The computer-based integrated approach successfully decreases the risk of ineffectiveness of the redesigned manufacturing operation. In the improved operation, optimum machine utilization results in both reduced time and availability of more spare time for workers to execute quality inspections resulting in improved quality products.

In the present manufacturing environment, new ways need to be found out to satisfy customer expectations while ensuring profitable growth. Manufacturers need powerful tools to achieve that top-notch performance improvement which will enable them to remain profitable and competitive.

An initial assessment should be used to map-out specific training and technology needs. The assessment should also be used to focus implementation on broader corporate objectives.

Benefits to a manufacturing process:

Reduce operational costs and increase the bottomline. Maximize team spirit and minimize errors. Standardize practices and methods Problems are identified first, before development and implementation of performance improvement solutions.

Six Sigma for Manufacturing involves advanced problem-solving and process analysis techniques. Using specially designed tools based on Six Sigma methodology, managers can measure, analyze and improve work processes. Six Sigma for manufacturing includes decision point analysis, process mapping and simulation modeling.

Value stream mapping : Using desktop programmes such as Microsoft Office Visio 2003, formulation of a value stream map can be automated.

Automated identification of value stream improvement places: Using analysis instruments like Microsoft Office Excel 2003, the value stream can be analyzed and scopes of improvement quickly identified.

Auto-generated value stream improvement plans: Using project management software such as Microsoft Office Project 2003, a template-run approach can be utilised to translate improvement opportunities into improvement projects.

Presently, there are a number of technical challenges associated with manufacturing process mapping. Different systems hold important data needed for effective value stream mapping. As no consistent way exists to collaborate on projects, many systems are required to be attached together.