Process flow chart in manufacturing | Symbols for process flow chart

A Process Flow Chart (PFC) in manufacturing is a diagram of the separate steps of a operations/process in sequential order. PFC also known as process flow diagram (PFD), and Process Map.

PFC is a process analysis tool that can be used to describe various processes, such as: Manufacturing process, Project planning, and Service sectors etc.

Process flow chart in manufacturing is one of the basic seven quality control tools or 7 QC tools and is widely used in quality problem solving methodologies like 8D and Six Sigma.

It is prepared during APQP and PPAP process for new product development, and one of the important document of PPAP lists.

When to use a Process Flow Chart

• For defining or analyzing new process.
• For standardize or redesign of a existing process.
• To find opportunity for improvement in a process such as unnecessary steps/activities, bottlenecks, and gaps etc.

Process flow chart types

There are mainly two types of process flow charts that are commonly used in manufacturing for quality improvement activities/projects.

1. High level Process Flow Chart
2. Detailed Process Flow Chart

High Level Process Flow Chart

 A high-level process flow chart provides a high-level picture/view (macro view of activity) of a process that generally having 6~10 main phases/steps. The major blocks of action/activity of a process are depicted in these process flowcharts. These charts are particularly useful in the early stages of a project and helps in the identification of improvement priorities.

Detailed Process Flow Chart

A detailed process flow chart depicts a process in detail (micro view of activity) usually greater than 15 phases/steps. Process flow charts of these kind are useful for identifying complexity, excessive steps, and other issues in a process and should be utilized when standardizing or modifying the existing process.

Symbols for process flow chart

The common symbols used for making process flow chart in manufacturing industries are shown below.

Key Elements of a Process Flow Chart

• Start or End : An elongated circle or ovals represents the start or end of a process.
• Arrows/Steps/Flow-lines: Represents direction of flow/process from one step to another.
• Process/Operation: Rectangle/square box shows instructions/actions/activity.
• Decision: Diamond box represents decision on particular activity.
• Storage: Represents storage of material/parts.
• Delay/Wait: Represents delay in operation/process/activity.
• Document: Represents supportive documents required.
• Start or End/Input or Output: Parallelogram is an alternate of elongated circle that also used to represents the start or end of a process.

Purpose of a Process Flow Chart (PFC) in Manufacturing

• Visualizes the workflow from RM (Raw Material) to final finished product.
• Identifies bottlenecks and inefficiencies present in the system.
• Ensures quality control by standardizing quality procedures and work instructions.
• Enhances process improvement through better clarity/understanding of processes.
• Helps in training new workers/employees.

Process flow Diagram | Key points

Following key points need to be addressed while making the manufacturing process flowchart or process flow diagram:

• Process flow diagram (PFD) reflect the complete process from receiving to shipping of product.
• Identify outsourced operations on the flow diagram.
• Identify stations where special characteristics are verified.
• Include sequence numbers and required manufacturing/inspection stations.
• Include identification of unique and/or dedicated process equipment.
• Include rework/repair operations, including re-inspection of the product.
• Process flow diagrams include packaging, labeling and storage.

Template for process flow chart

Download Process flow chart template power point & process flow chart word template