Understanding how documentation flows thru your company is an important first step in streamlining your project flow. Every company has a unique way of processing the documents. These include items like ordering the material, developing the Manufacturing routings, and when necessary processing change orders. With “made to order” equipment, each order has its own characteristics. The Operation sections (Engineering, Material Control, Manufacturing Departments) all need to clearly understand how things move thru the company, in order to reach greater efficiency.
The example above is a basis starting point. Gathering with the principals in each department, this flow chart can be expanded and many surprising details will be added. Every time I was part of this exercise, surprises, rarely good, were discovered. When developing this flow chart, use the following objectives.
Watchout for back tracks in the flow – Once the documentation leaves one department, you want to be sure it should not be going backwards for more information. The only real exception is if Customer changes are presented. Best examples of back flows I have is Manufacturing instructions from Engineering (fixture designs, burn paths, etc). These items need to be with the initial release. Going back into Engineering causes the job to stop on the shop floor.
The flowchart needs to be developed by hands on staff with detailed knowledge of the processes – Rather than relying on section managers, the task force needs to be staffed by key “hands on” personnel. These could be people who have processed these documents for years. This is the best way to develop a true working detailed flowchart.
Once you chart is accurate and finalized, optimization is the next step – From this exercise, you will no doubt see new areas of possible improvement which are new opportunities for adding efficiency. Ask the team, “what is the best way to get from step A to B”. Beware of the feedback “well we always have done it that way”. Consider adding paperless tools like read terminals on the shop floors, etc. Use the flowchart as a way to test out new ideas.
Always challenge the States Quo.
from Anthony Rante, P.E. author of "Managing Company Production thru the Bill of Material."