chapter 2 of process systems analysis and control book by Donald CoughanowrFull description
Communication is the way toward sending and getting messages through verbal or nonverbal means, including speech, or oral communication composing and graphical portrayals, for example, info graphics, maps, and diagrams and signs, signs, and conduct.
You are holding a book for project managers, process designers, operators, engineers and decision makers in the oil and gas industry to optimize risk-based decisions and get things done.
Structural Analysis and Design of Process EquipmentDescripción completa
Purchasing (7.4) Supplier selection/ development Monitoring of supplier Purchasing process
How? (Methods/ Procedures/Techniques Procedures/Techniques)) Purchasing procedure Supplier selection Supplier performance monitoring Supplier development process E-mail •
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Output Contour purchased product conform to spec. On-time receiving •
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With What Key Criteria? (Measurement/Assessment) Cost of poor material receiving Timeliness (on-time) Material/ product quality Procedure material shortage Premier freight •
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Annex B
Process Audit Preparation “Turtle Diagram” With What? (Materials/Equipment) Material, component Production machine/equipment Molding, pressing, assembly Inspection tools, gauges Assembly jigs Component parts •
With Who? (Competence/Skills/Training) Trained operator QC
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Inputs QMS requirement Feedback of information from service Customer requirement Special characteristic Production schedule Delivery schedule Regulatory requirement Quality target •
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Process Defrost grill assembly
Output Defrost grill conform to customer requirement/ regulatory •
How? (Methods/ Procedures/Techniques Procedures/Techniques)) Control Plan Work instruction for job set up u p verification Inspection/ Test instruction SPC Error proofing Procedure of stamping, molding •
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With What Key Criteria? (Measurement/Assessment) PPM Quality Cost Delivery performance Time for return product test/ analysis and problem solving Response time Cpk •
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Annex C
Process Audit Preparation “Turtle Diagram” With What? (Materials/Equipment) Purchasing data base BOM
With Who? (Competence/Skills/Training) Trained purchasing Staff
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Inputs Delivery schedule Supplier schedule Approved supplier list Customer requirement Approved source Purchase requisition Regulatory requirement Records of supplier performance Product requirement (design record) Production schedule Acceptance criteria
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Process Purchasing (75% component of 7.4.1) Are outsource from 2 suppliers
How? (Methods/ Procedures/Techniques Procedures/Techniques)) Supplier selection procedure Supplier development method Purchasing procedure Purchased product control instruction •
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With What Key Criteria? (Measurement/Assessment) Timeliness Cost of material (part) Quality of materials (part) Quick resource for any problem concerned with material/part •
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Annex D
Process Audit Preparation “Turtle Diagram” With What? (Materials/ Equipment) Process equipment & machine Testing machine Material •
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With Who? (Competence/Skills/Training) APPQP team members who trained and skilled in applicable tool FMEA, DOE, QFD •
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Inputs Customer requirements e.g. Special characteristic Process Approval requisition DFMEA Establishing Previous design projects & updating Field data (7.1, 7.3) Block diagram Preliminary process flow chart Material specification How? (Methods/ Procedures/Techniques Procedures/Techniques)) WI, Procedure far-forging Testing method/destructive testing (tensile) Poka yoke DOE Feasibility review method Part approved process •
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Output DFMEA which can prevent tensile strength failure
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With What Key Criteria? (Measurement? Assessment) Fail rate PPM Defect rate •
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Annex E
Process Audit Preparation “Turtle Diagram” With What? (Materials/ Equipment) Safety equipment Transportation equipment Forklift Truck/tailor Strapping machine Finished product Computerize system for product picking
With Who? (Competence/Skills/Training) Trained personnel Qualified Driver
How? (Methods/ Procedures/Techniques) Handling & delivery work instructor Labeling requirement Packaging requirement On-time (EDI) system Training procedure •
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With What Key Criteria? (Measurement? Assessment) On-time delivery performance Error rate Customer satisfaction score No customer complaint/clai complaint/claim m Field return report Premier freight •
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Annex F
Process Audit Preparation “Turtle Diagram” Inputs Customer requirement/SC DOE Block Diagram DFMEA Timing plan Regulatory requirement Functional & performance requirement Previous similar design Field data Competitor analysis Timing plan Preliminary process flow chart Design goal •
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With What? (Materials/ Equipment) CAD/CAM •
With Who? (Competence/Skills/Training) Product design skill personnel •
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Output Designed product Meet design input Design records e.g. drawing
Process
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Design (7.3) (input output)
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How? (Methods/ Procedures/Techniques Procedures/Techniques)) Design procedure APQP manual Math •
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With What Key Criteria? (Measurement/Assessment) Design error rate Drawing compliance Product life Timeliness •
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Annex G
Process Audit Preparation “Turtle Diagram” With What? (Materials/Equipment) Overhead Meeting room
With Who? (Competence/Skills/Training) Top management & management team
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Inputs QMS requirement Business plan Process performance and analysis Field failure/impact Submit result Customer feedback CA/PA status Follow up action form previous Recommendation for improvement Policy/object Product conformities Yearly plan IQA Plan Quality poling/objective framework identification •
Process
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Management Review (Target 5.6)
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Output Decision & action related to Improvement process, QMS Product related customer satisfaction *recommendation *recommendati on for improvement •
With What Key Criteria? (Measurement/Assessment) Customer satisfaction Improvement trend (of process/product) Status of CAR/PAR External nonconformities •
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Annex H
Process Audit Preparation “Turtle Diagram” With What? (Materials/Equipment) Internet Telephone Customer P/O
With Who? (Competence/Skills/Training) Trained staffs
How? (Methods/ Procedures/Techniques Procedures/Techniques)) Contact review procedure WI APQP manual Feasibility review process •
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With What Key Criteria? (Measurement/Assessment) Sale volume Win in bidding No. of enquiring/order? •
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Process Audit Preparation “Turtle Diagram” With What? (Materials/Equipment) CAD/ CAM Program Computer Raw material Strength test equipment Inputs Customer requirement ECN Regulatory requirement Previous similar design Target for product quality
With Who? (Competence/Skills/Training) APP Team Product design engineer Process design engineer
Design & Development
How? (Methods/ Procedures/Techniques Procedures/Techniques)) Strength test institution APQP Manual PPAP Procedure FMEA Manual Control Plan
Output Product conform to strength test specification
With What Key Criteria? (Measurement/Assessment) PPM Scrap rate Cpk
Process: Process design & development Process owner: APQP Team Process Input; •
Customer requirement
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ECN
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Regulatory requirement
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Previous similar design
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Target for product quality
Process Activities •
Design Planning
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Design input review
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Design output review
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Design verification
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Design validation
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Design change control
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PPAP
Support Activities •
Production; preparation of work instruction, train operator
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QC; inspection, MSA
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Maintenance; tools equipment making/ maintenance
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Sale; receiving of customer requirement & feedback
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Management; Management review
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Purchasing; purchasing of material
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HR; Training
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Engineering; packing standard etc.
Interface/ Linage Output
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Customer Supplier HR Production Maintenance
Process flow diagram Drawing Special Characteristic FMEA Control plan Working struction/ Job instruction Product for approval
Measurement •
Time
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Correctness
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Ppk > 1.67
Reference Document/ Necessary Information •
APQP Procedure
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Customer requirement
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Regulatory requirement
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Functional requirement
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Company policy
Material/ Equipment
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Computer (CAD/CAM)
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Sample part
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Jig/ Fixture
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Production machine (press, machining, etc.)
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Inspection tool
Process Audit Preparation “Turtle Diagram”
ทด้ ด้วยอะไร วยอะไร)
With What? ( (Materials/Equipment) Spare part Special purpose tools Measuring equipment
ทโดยใคร โดยใคร
With Who? ( ) (Competence/Skills/Training) Trained personnel (Service)
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ผลลัพธ์ พธ์
ใช้ข้ขอ้ มูลอะไร ใช้ ลอะไร
Inputs ( ) Warranty period document Customer specific requirement •
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ทอย่ อย่งไร งไร
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Process
Servicing Repair Maintenance Service agreement (7.5.1.8)
How? ( ) (Methods/ Procedures/Techniques Procedures/Techniques)) Work instruction Service Manual •
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Output ( ) Service provided within Warranty period On-time correct service Conform to customer requirement •
With What Key Criteria? ( ) (Measurement/Assessment) Timeliness Error rate No returned job with some issues & side effect
วัดผลลั ดผลลัพธ์ พธ์ด้ดวยเกณฑ์ ว้ ยเกณฑ์อะไร อะไร
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1. Process Input (what do you need?) •
Warranty period document
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Customer specific requirements
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Service agreement and contract (
จะเป็น output ถ้เป็ จะเป็ เป็น 7.2
จะเป็น input ถ้เป็ เป็น 7.5 audit)
audit, •
Work instruction
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Trained personnel (skill, experience)
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Any special purposed tools or measuring equipment
2. Process Activities •
Pre-inspection/ diagnosis
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Repairing Service
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Maintenance Service
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Testing
3. Support Process •
Contract Review
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Feasibility Review
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Training
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Production part/ spare part
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Tools & equipment maintenance
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Cost estimation
4. Linkage/ Interface •
Customer
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Engineering
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Safety
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Financial
5. Process Output •
Service conformed to customer
6. Measurement (for process efficiency & effectiveness) •
Timeliness (Response time)
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Field return rate (Returned job)
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Error Rate
7. Audit Planning (Activities for preparation) •
Identify Process
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Analyze Process
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Risk Analysis (input/output) and Audit Prioritize
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Follow up issue for previous audit
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Internal and External
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Audit plan (Sequence/ process step, timing, interview partners) Create complete checklist
8. Fact verified during the audit •
Are those any organization service center?
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Any special purposed tools
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Who conducted diagnosis, repair, maintenance?
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What are services documents?
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Are spare parts appropriate provided?
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How is inspection/ Testing conducted
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Are measuring drive calibrated? How long does service taken?
Analysis of Internal Audit Process
ทโดยใคร โดยใคร
With Who? ( ) (Competence/Skills/Training) Independence Trained Ski Export
ทด้ ด้วยอะไร วยอะไร)
With What? ( (Materials/Equipment) Audit checklist Turtle diagram
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ใช้ข้ขอมู ใช้ อ้ มูลอะไร ลอะไร)
Inputs ( Objective Frequency QMS requirement QMS Status Customer Complaint Nonconformities •
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ผลลัพธ์ พธ์
Internal Audit (QMS Audit)
Output ( ) Known QMS status of QMS •
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ทอย่ อย่งไร งไร
How? ( ) (Methods/ Procedures/Techniques Procedures/Techniques)) Work instruction Service Manual •
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With What Key Criteria? ( (Measurement/Assessment) Strength Weak point/ observation Nonconformities Improvement items No. external nonconformities
