flowchart
TRANSCRIPT
Order Management Flowchart (January 1, 2002)
Is there a new drawing with the PO?
Follow process for receiving drawings.
Yes Receive Drawings Chart.
No
Was written confirmation sent?
No
Was PO information complete?
Yes
Yes
Yes
Do price and quantity on PO match quote?
No Contact Management for further instructions.
Continue with new information?
No
Wait for new PO.
No Contact customer to obtain missing information.
Contact customer for written confirmation prior to beginning, unless otherwise specified by management.
Customer sends PO.
Yes
Enter PO in database as a Work Order.
Confirm PO to customer according to customer’s wishes.
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Is the assembly a new one?
Yes
Is the latest drawing available?
No
YesAre changes required to D&I or BOM?
Have appropriate personnel review assembly and note changes.
Document changes on form
Make a sample according to changed documents.
Verify sample against customer drawing
Are changes required?
Yes
Record results on form.
No
“New Assembly” Process rejoins Main flow.
New Assembly Chart.
Yes
Is a test fixture available?
No Order parts for a testfixture (mating connectors).
No
Change documents.
Contact customer for latest drawing.
No
YesNew assembly Chart
Follow the procedures for a “new assembly”
Print a “Materials Required” Report and use the BOM to determine the materials that must be ordered.
Make proper scrap allowances.
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Yes
NoDoes current pricing match the pricing in quote?
Re-quote assembly for customer. Re-start Order process if customer accepts new quote.
Contact management for instructions on re-quoting or proceeding.
Obtain material pricing from vendors.
Check the vendor approvals.
Search inventory for existing stock.
Continue.
Document PO’s in database and print PO’s for vendors.
Is a labor estimate available?
Schedule the WO in the places required using the labor estimate as a guide.
Yes
NoEnter labor estimate in database.
Obtain a labor estimate from management.
Adjust inventory levels for order (subtract requirements).
Order materials from vendors.
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Does material conform?
No
Yes
Update inventory levels to account for received material.
Print all documentation for WO jacket.
Follow Management instructions for replying to vendor and dealing with the invoice.
Does Invoice price match quote& PO price?
Apprise Management of the explanation.
Contact vendor for anexplanation of pricing discrepancy.
Issue WO to floor when sufficient materials are available to begin.
Production teams draw material from inventory.
Document material draw in appropriate database.
Receiving additional materials.
Decide the type of production for the order: small, large, or special.
Follow “RMA” procedures to return material.
Inspect material according to incoming material standards.
Receive materials as they arrive.
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Are more materials to arrive?
Receive materials as specified above as they arrive.
Yes
No
Prepare cable according to Assembly Instructions.
Inspect cable according to standards.
Document inspection results in database.
Does material pass inspection?
Sort material to remove non-conforming material according to Sort procedures (See Chart).
No
Yes
Terminate according to Assembly Instructions.
Inspect material according to standards.
Document inspection results in database.
Yes
Does material pass inspection?
Sort material to remove non-conforming material according to Sort procedures (See Chart).
No
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Perform electrical tests according to Instructions.
Complete according to Assembly Instructions.
Yes
Do cables pass inspection?
Sort material to remove non-conforming material according to Sort procedures (See Chart).
No
Document electrical inspection results in database.
Perform mechanical tests according to Instructions.
Document mechanical
inspection results in database.
Yes
Do cables pass inspection?
No
Sort material to remove non-conforming material according to Sort procedures (See Chart).
Count the cable
assemblies to ship.
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Report count to office.
Make a packing slip for the shipment.
Pack according to shipping standards and Instructions.
Enter final record in shipping log.
Reconcile shipping log and packing slip
Calculate shipping and handling costs and enter them in database.
Print invoices and mail them to customers. Keep one copy for records.
Yes
NoRepeat process for each additional release.
Is order finished (no more releases)?
Return unused inventory.
Calculate scrap from inventory draw and return records.
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Customer returns?
Log return in database.
Sort material to separate non-conforming material according to steps in Sort Chart.
Determine problem(s).
Rework or replace material based on Production, Inspection, and Management instructions.
Return material to customer.
CAR documentation required?
Yes
Follow customer CAR instructions.
Document return and remedy.
NoYes
No
Document changes.
No
End
Follow change procedures for previously produced assemblies.
Are D&I or BOM changes required?
Yes
Follow up with customer if invoice not paid in forty days.
Submit WO jacket to management for review and approval.
Finalize and collect WO documentation.
Make closing entries for WO in database.
Adjust inventory levels from scrap calculations.
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New Assembly Flowchart (January 1, 2002)
Verify the BOM.
No.
Use customer information to create an internal drawing and instruction set (D&I).
Make a sample cable assembly using D&I.
Inspect the sample assembly against the customer’s drawing.
Print new D&I.
Enter BOM in the database.
Use BOM to purchase materials.
Yes.
Is BOM correct?
Change BOM as required.
Review customer drawings and documentation to develop a BOM.
From Main Flowchart for New Assemblies.
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No.
Is proper tooling available?
Inform Management and obtain proper tooling.
Yes.
Return to Main Flowchart for test fixture procedures.
Yes.
No.
Change D&I.Document changes on a Change Form.
Determine the changes required.
Is the sample correct?
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Drawing Record Flowchart (January 2, 2002).
Enter the P/N, date, drawing date, and Rev. level in database.
Sort the database for all entries pertaining to this P/N.
Yes.
Has the date or Rev. level changed with the present drawing?
Indicate “No changes” in the database record and continue to use present set D&I.
File drawing and stop.
No.
Determine the differences, if any, between the present drawings and the previous set.
Yes.
Are there any changes?
No.
Note the changes between the drawings.
The first drawing entered in the database for each new assembly should be the one accompanying the first quote or RFQ.
Customer sends a drawing of a cable assembly (every time).
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No.
Are the changes significant enough to change the price of theassembly (Consult Management if necessary)?
Submit the new drawings to Management to re-quote the assembly. Submit quote to customer.
Record the changes required on a Change Form and submit for approval.
Change D&I according to change form.
Produce a new D&I and destroy old D&I.
Follow the procedures for a “Changed” assembly for thenext PO (samples, etc.).
Note the changes made in the database for future reference.
Use these records to determine whether the most current version of D&I are being used.
Yes.
File drawing and stop.
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Re-Quote Flowchart (January 2, 2002) [When prices no longer account for costs]
Inform customer that their order is on hold until the assembly can be re-quoted.
Wait for customer response to new price.
Management re-quotes assembly.
Obtain pricing data for assembly’s BOM and laborrequirements.
Assembly price no longer reflects material or labor costs and Management deems it necessary to re-quote assembly to customer.
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RMA Flowchart (January 2, 2002) [Returned Materials Action]
Separate failed material.
Note the discrepancies and inform the vendor.
Fill out RMA form with correct information.
Follow vendor’s instructions and return material to vendor.
Obtain an invoice credit from vendor.
Obtain the proper materials from the vendor.
Material fails the incoming inspection.
Follow up with vendors as required to obtain new materials and address payments.
File RMA form and return to Main Flowchart using new material.
Material found to be defective.
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Sort Procedure Flowchart (January 2, 2002)
Remove all non-conforming (failing) assemblies and place in a clearly marked receptacle.
Inspect each assembly in lot for dimension or attribute in question.
From a failed Inspection on Main Flowchart.
No.
Document the waiver in written form and insert into the WO.
Thoroughly inspect the reworked assemblies.
Rework assemblies according to procedure.
Determine the procedures for reworking the assemblies.
Follow the parameters of the waiver for using the material.
Yes. Is waivergranted?
Determine the statistics or extent of failure. Ask Management if a waiver can be obtained (where appropriate).
Yes.
No.
Scrap the failed assemblies and replace them with new ones.
Can failed assemblies be reworked?
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Return the passed material to the production flow for use.
Return to the Main Flowchart Inspection procedures.
Fill out the sort form with the statistics and results of the sort.
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