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1、Process Flow Diagram (PFD)Energy & Chassis Systems2/14/2002 PFD TrainingEnergy & Chassis Systems2 PFD Training Rev 4Characteristics DeploymentEnergy & Chassis Systems3 PFD Training Rev 4Backgroundu“Hidden Factory” issues continually affect Delphis quality performance and remains essentially undocume
2、nted Rework parts bypass process controls Mixed parts at changeovers Quality audit and scrap parts finding their way back into the processuNeed for common systems Part of the overall Delphi Business Strategy Inclusion into the Delphi Engineering System common content, common format, common approach
3、Extend the approach to our suppliers considered an extension of the Delphi processesEnergy & Chassis Systems4 PFD Training Rev 4What is a PFD?uDefinition: A Process Flow Diagram is a flow chart linking individual process steps to form a manufacturing system.uScope: Identify every possible path a par
4、t can take through the anticipated manufacturing process DP268 Encompasses the “Hidden Factory” Quality Audits Rework Processes Alternative Processes Scrap ChangeoversEnergy & Chassis Systems5 PFD Training Rev 4Why a PFD?uA comprehensive and detailed PFD is the starting point for documenting the man
5、ufacturing process. Graphical representation of the manufacturing process Essential foundation for a PFMEA - “Roadmap” Springboard for process documentation - PFMEA, PCP, Routing, uHelps in developing equipment specifications. How should the process control non-conforming material? How will inspecti
6、ons be performed, what is required? How will parts be re-introduced into the process?uHow does an enhanced PFD help develop the PFMEA? Organized to help see the entire process changeover, fab, inspect, rework, scrap, move, store, audit Identifies Significant Product and Process Characteristics Produ
7、ct Characteristics = Outputs = Potential Failure Modes Process Characteristics = Inputs = Potential CausesEnergy & Chassis Systems6 PFD Training Rev 4Preliminary PFDuA preliminary PFD is typically a simple block diagram that shows the main operations. Generated during Manufacturing Systems Design wo
8、rkshopsEnergy & Chassis Systems7 PFD Training Rev 4PFD Excel WorksheetuInstructions and reference information can be found by viewing the commented cells (those with the small red triangle in the corner).uThe Excel workbook also contains a Help worksheet for instructions on drawing symbols, connecto
9、rs, etc.Energy & Chassis Systems8 PFD Training Rev 4Operation-Sequence #u“Operation” Op-seq major process steps (by tens): 10-, 20-, 30-, 40- . established by a preliminary PFD (process block diagram)uSequence” op-Seq individual detailed steps within a given operation. Sequenced by one: #-1, #-2, #-
10、3, #-4 .uNotes: The PFD establishes the Op-Seq numbers and they must match the PFMEA, Control Plan, and other process documentation.uOperation Description: describe what is happening to the part.not a machines sequence of operation or an operators standardized work. Energy & Chassis Systems9 PFD Tra
11、ining Rev 4PathsuDashed paths show the “Hidden Factory” rework, scrap audits errorproofing verification part flow alternative (backup) processesuRed paths: Reject part flow Rework part flowuPaths between symbols are drawn using Excel AutoShape Connectors - not linesEnergy & Chassis Systems10 PFD Tra
12、ining Rev 4Fabu“Fab” value-added activities that change the state of the part machining, labeling, chemical, assembly, welding, paint, etc.uSig. Characteristics what product characteristic(s) are a result (output) of the fab step? KPCs or QCIs? what process characteristic(s) control the associated p
13、roduct characteristic? KCCs or QCCs?Energy & Chassis Systems11 PFD Training Rev 4PFMEA Link (Fab)Product Characteristics (Outputs)translate intoPotential Failure Modes Process Characteristics (Inputs)translate intoPotential Causes Energy & Chassis Systems12 PFD Training Rev 4Store/Get and Moveu“Move
14、” parts are moved within the process parts in a storage device are relocated (dock to supermarket)u“Get” starting point - parts are introduced to the process from a storage or presentation deviceu“Store” ending point - parts are returned to a storage device parts are located in a bufferEnergy & Chas
15、sis Systems13 PFD Training Rev 4InspectionsuRed, Yellow, Green shading can be used to show test results and their respective pathsuNotice the flow of Master parts into and out of automatic inspections Show where parts go if they are be removed from a nest to perform the errorproofing verification. u
16、Letter inside the box indicates type of inspection V = operator visual M = operator manual gaging Q = quality audit A = automaticEnergy & Chassis Systems14 PFD Training Rev 4Reworku“Rework” replace, repair, reload, tear -down, retest, etc. rework can take place online or offline considered part of the processuRemind
