GEA's Global HVAC Technology Blog Blog

GEA's Global HVAC Technology Blog

GEA's Global HVAC Technology Blog covers a range of topics including:

  • Core HVAC Technologies
  • Technology & Patent Evaluation
  • Manufacturing Technologies
  • Product Quality Improvement
  • Materials/Failures/Corrosion
  • Product/Technology Commercialization
  • Business Strategy Development
  • New Factory Design & Equipment

We'll draw upon our range of experts to provide comments, insights, technical articles and a little humor from time to time

We encourage your participation and feedback!

Previous in Blog: Understanding Oil Return in Refrigeration Systems (Part 3: Liquid in the Compressor Suction)   Next in Blog: The Best HVAC Videos
Close
Close
Close
6 comments
Rate Comments: Nested

Flow Charting: Step One in Procedure Development

Posted February 02, 2011 9:00 AM by geanorm

Editor's Note: CR4 would like to thank Ed Eisermann of GEA Consulting for contributing this blog entry.

The first task in developing a procedure is to prepare a flowchart of the current practice. This is done with the active contribution of staff who do the task or know most about the task.

The procedure author/facilitator leads the group and prepares a rough flowchart of the current process. The flowchart emerging in the meeting should be rich in detail through the contributions of all participants, but it will also be a mess - marked up with deletions, changes, and notes added as a result of the group's inputs. Seldom can this be done in one meeting unless the process is simple. All participants should bring any work instructions and check sheets that they use or have concerning the process to the meeting for reference and use in the discussion, and to be included in the project file for future reference.

The author and team should consider whether it may be beneficial to cover some of the tasks in multiple separate procedures - there are no hard and fast rules. The best approach is to assure a clear and easy understanding of the process. All that can be said is that a flow chart generally is easier to use if it less complex. Also, if a flow chart focuses on one process or functional area it provides easier future change and control.

Remember these documents need to be changed as the process is improved and become controlled documents if they remain in the system.

Following the meeting, the team leader creates a legible flow chart (with assistance as needed). Use of a flow charting software program is recommended. The supplemental documents discussed above should be numbered and where used be so indicated on the flow chart.

This created flow chart can be used in the following manner:

  1. If the process is correct as drawn and changes in the process are not planned, the chart can become the procedure without creating a word document. It should however be given a number, be dated, have a revision level and show an "approved by" name.
  2. If the process is correct as drawn and changes are not planned, a written procedure can be created with the flow chart being an appendix to the created document.
  3. The team can use the created chart as a starting point to discuss improvements to the current process with a goal of removing any "non-value added" activities, added check points and improve process flow.
  4. Complete a revised flow chart and apply it as shared in steps 1 or 2 above.

Regardless of the approach used to maintain the flow chart so that it reflects the true description of the process that is to be followed by the organization, it should be reviewed on a defined schedule to ensure that it is current with the practice. The best practice is to change the flow chart every time the process is changed through a formal change control process. Also, always remember that those positions described in the flow chart must receive communication on the changes, instructed to follow the revised process and to discard any non-controlled copies in files.

- Ed Eisermann

Reply

Interested in this topic? By joining CR4 you can "subscribe" to
this discussion and receive notification when new comments are added.
Anonymous Poster
#1

Re: Flow Charting: Step One in Procedure Development

02/07/2011 11:46 AM

Hi Ed,

Yes, without flowchart there is no profitable processes and operations. Before you start to do something, you put on paper a flowchart indicating the best way to do the work by putting raw materials, handling and working equipment and tools, and place for the finished goods. The flowchart could be linear or U-shaped or other cellular.

If you have the duty to establish a flowchart on existing workshop, follow the process creating the object the company does by being behind workers and notifying what's happening timely. Study efficiency, improve it, and eliminate wastes. The only meeting worth a dollar, when after the study, improvement, and elimination of wastes, the process is better than before, ask working people what they suggest to improve and can be eliminated. Listen to them and take notes. Redo the flowchart and study again for new improvements. The final flowchart is used to write the new standard operating procedures. Now, you can start over again and redo the flowchart for improvement of this new process, Gil.

NB: Improvement is a continuous process for better performance!

Reply
Commentator

Join Date: Dec 2010
Posts: 55
Good Answers: 1
#3
In reply to #1

Re: Flow Charting: Step One in Procedure Development

02/17/2011 10:13 AM

Gil, your comments show that you are far ahead of the pack. I wrote this paper for the beginner...someone who works for a new start-up business, a growing business that needs some controls, or one that has significant staff turnover. Writing a procedure is like writing a book. You need an outline..in the case of a procedure..the flow chart is the outline. Using the flow chart the sequence of activities and who is responsible, the required tools and forms that are needed become part of the documented procedure. As I prepared to respond to your observation, I reread the paper and realized that one additional use of the procedure/flow chart that I did not list is aguid for internal and external auditors. I also like the flow chart for team process improvement activities discussions...the old saying "a picture is worth a 1000 words". It is much easier to understand the flow of a process from looking at a flow chart than reading a complex dry procedure. I did not discuss policies... which I view as a view of a group of processes from the 10,000 foot level . The procedure is a view from the 1000 foot level and below that are work instructs, travelers and check sheets at ground level. I expect to see work instruction, traveler and check sheet changed 10 times for each time the procedure needs to be changed and a policy maybe once for every 5 changes to a group procedures in a continuous improvement environment. Again Gil, all that you said is accurate and true in a continuous improvement environment, a condition that does not exist in many businesses...I am sure you know the expression; "if it isn't broke don't fix it". The best companies are moving and changing things continuously...that is why computers and monitors and the elimination of paperwork to allow making changes on the fly is the only way to run a business today, but one must not forget that changes made without communication/training of all in the process chain will resulting in errors. Gil would appreciate your comments on my recent paper on the internal supplier-customer interaction. It may not be on the blog...check it out on the GEA web site Edward Eisermann

Reply Off Topic (Score 5)
Anonymous Poster
#5
In reply to #3

Re: Flow Charting: Step One in Procedure Development

02/22/2011 10:56 AM

Hi Norm,

To talk about: "Using the flow chart the sequence of activities and who is responsible, the required tools and forms that are needed become part of the documented procedure", I want to tell you that in any manufacturing organization, start-up or established business, the management is responsible for the quality of the produced items.

When the flow chart is correct, the standard operating procedures describe what and how to do things to achieve the final object as quality item, the worker just follow what is written and create good finished items.

This must be done by small companies to achieve success. The entrepreneur has knowledge about his endeavour. She/he teach everyone what and how to do everything. This is the principle that most business people must follow to stay in business and/or grow to big and successful, Gil.

Reply Off Topic (Score 5)
Commentator

Join Date: Dec 2010
Posts: 55
Good Answers: 1
#4
In reply to #1

Re: Flow Charting: Step One in Procedure Development

02/17/2011 10:14 AM

Gil, your comments show that you are far ahead of the pack. I wrote this paper for the beginner...someone who works for a new start-up business, a growing business that needs some controls, or one that has significant staff turnover. Writing a procedure is like writing a book. You need an outline..in the case of a procedure..the flow chart is the outline. Using the flow chart the sequence of activities and who is responsible, the required tools and forms that are needed become part of the documented procedure. As I prepared to respond to your observation, I reread the paper and realized that one additional use of the procedure/flow chart that I did not list is aguid for internal and external auditors. I also like the flow chart for team process improvement activities discussions...the old saying "a picture is worth a 1000 words". It is much easier to understand the flow of a process from looking at a flow chart than reading a complex dry procedure. I did not discuss policies... which I view as a view of a group of processes from the 10,000 foot level . The procedure is a view from the 1000 foot level and below that are work instructs, travelers and check sheets at ground level. I expect to see work instruction, traveler and check sheet changed 10 times for each time the procedure needs to be changed and a policy maybe once for every 5 changes to a group procedures in a continuous improvement environment. Again Gil, all that you said is accurate and true in a continuous improvement environment, a condition that does not exist in many businesses...I am sure you know the expression; "if it isn't broke don't fix it". The best companies are moving and changing things continuously...that is why computers and monitors and the elimination of paperwork to allow making changes on the fly is the only way to run a business today, but one must not forget that changes made without communication/training of all in the process chain will resulting in errors. Gil would appreciate your comments on my recent paper on the internal supplier-customer interaction. It may not be on the blog...check it out on the GEA web site Edward Eisermann

Reply Off Topic (Score 5)
Anonymous Poster
#2

Re: Flow Charting: Step One in Procedure Development

02/11/2011 11:39 AM

Hi Norm,

Thinking about what is your question and my previous answer, I have to add when you already have a FLOWCHART but it's not satisfactory. Problems with the product or the process making it? You have to establish what must be done. To redesign the process or the product or both together because one influences the other. In any case, you have to redo the FLOWCHART, it takes new equipment tools, relocation of those, and many other changes must be noted.

It will be important to redo the FLOWCHART again because we cannot predict the future performance with precision, Gil.

Reply
Commentator

Join Date: Dec 2010
Posts: 55
Good Answers: 1
#6
In reply to #2

Re: Flow Charting: Step One in Procedure Development

02/22/2011 3:40 PM

Hi Gil, in a very small business where the entrepreneur is part of the work crew that provides the service or product, I can agree with what you said in your last two sentences. BUT In large companies this is not possible; MANAGEMENT can only create the environment and provide the resources to drive production of a quality product or service. Oh, I neglected to add "management also creates the environment to improve housekeeping, safety, worker attitude and productivity improvement". During my career, I once was given the chance to mange a plant with 175 hourly employees that management was considering closing. Poor efficiency, poor safety, poor quality and attitude. These people would go to the local watering holes after work and just complain. In 18 months, with no change in documentation, but me spending 6 hours each day on the floor communicating, weekly meetings with the union stewards and foreman; the plant's performance went from worst to best on the campus of 6 facilities. The policies, the procedures, the work instructions and the training were and had been in place for years. What changed? I tried to talk to every employee each day and listened, when appropriate I took action. The people not me changed the plants performance. All that I provided was an ear, the environment and the resources. In fact, Quality Progress, the American Society for Quality came to the plant to see the plant,talk to the people and then published an article in the April 1987 issue about the plants turnaround. Ed Eisermann (author) GEA Consuting

Reply
Reply to Blog Entry 6 comments

Previous in Blog: Understanding Oil Return in Refrigeration Systems (Part 3: Liquid in the Compressor Suction)   Next in Blog: The Best HVAC Videos

Advertisement