UNIVERSITY

CONTINENTAL
THIRD UNIT
ANALYSIS OF THE FLOW OF THE PRODUCTION PROCESS

PROCESS ANALYSIS TOOLS

DIAGRAM OF PROCESS OPERATIONS – DOP

PROCESS ANALYSIS DIAGRAM – DAP

Process diagrams are schematic representations of a process in a company, which are used to analyze
and optimize it.

CONVENTIONAL SYMBOLS

A. Operation: Used to indicate the main steps of the process, method or procedure. The operation
takes place when the physical or chemical characteristics of an object are
intentionally modified, disposed of or prepared for another operation,
transportation, inspection or storage. An operation also occurs when the
operator provides or receives information and when he plans or calculates.

B. Inspection: Takes place when an object is examined to identify it or when the

quality and/or quantity of any of its characteristics is verified.

C. Transportation: Used to indicate the movement of workers or the path followed

by materials when they are moved from one place to another (minimum
distance: 1.5 m). It does not include movements that are part of an operation or
inspection, or when caused by the operator at the workstation.

D. Wait: or provisional deposit, used to indicate stagnation or inactivity of a

material during a production process. It occurs when an object or person waits
for the next planned action. It does not include those that intentionally change
the physical or chemical characteristics of the object of study.

E. Storage: Indicates deposit of an object under surveillance in a warehouse, where

it is received or delivered through some form of authorization, which is kept for
reference purposes. It occurs when an object is stored and protected against
unauthorized removal.

F. Combined (Operation-Inspection): Activity that indicates an operation and

inspection, which are carried out simultaneously and almost at the same time.

PROCESS OPERATIONS DIAGRAM - DOP

This diagram shows the chronological sequence of all operations, inspections and
materials used in the manufacturing process, from the arrival of raw materials to the

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packaging of the finished product.

The graph describes the input of all components and subassemblies to the main assembly,
schematically represents a production process, using only the operation, inspection and combined
symbols. An operation takes place when a part under study is intentionally transformed, an inspection
takes place when the part is examined to determine its conformity to a standard.

The preparation of this diagram requires using vertical and horizontal lines, in which the components
of the product, all the operations and inspections of each of them and the inputs and outputs of
auxiliary materials must be indicated.

PDO structure

The DOP has 3 parts:

1. Header : Indicates the title of the diagram and the type of product being produced. You can also
enter other data such as date, section, operator, etc.
2. Body : It is the diagram itself, made up of symbols, vertical and horizontal lines.
3. Summary : Indicates the total number of operations, inspections and combinations carried out.

Rules for preparing a DOP

1. Only the operation, inspection and combined symbols are used, from top to bottom.
2. The main component or raw material should be placed on the right of the diagram. It is
recommended that the other components be placed from right to left at the top of the diagram,
in decreasing order of importance.
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3. To the right side of each symbol is a brief description of the activity (maximum 3 words).
4. There should be no crossings between lines.
5. The symbols must be exactly the same size.
6. The mood of the verbs must be the same for all operations. The infinitive mood is recommended.
7. All inputs and outputs to the system must be clearly established by horizontal lines (inputs must
go to the left of the vertical line and outputs to the right). Brief descriptions are noted above the
arrows.
8. When waste occurs, a line is placed to the right, indicating the causes.
9. Every time substantial changes are made to the product, they are indicated with two parallel
lines and between them the change information.
10. If there are bifurcations in the process, these must be represented in the diagram.

11. In the case of repeated activities, two parallel lines are placed and between them the number of
repetitions. A bracket is placed on one side that identifies which activities include the repetitions.
In a similar way it is done for reprocessing.

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12. All operations and controls must be properly numbered. Numbering is done from top to bottom
and from right to left.

Construction of the DOP

Before beginning construction of the DOP, the analyst must identify the diagram with a title “Process
Operations Diagram” and other information such as part number, drawing number, process
description, current and proposed method, date and name of the person who makes the diagram.
Additional information may include diagram number, floor, building, and department.

The vertical lines indicate the general flow of the process in performing the work, the horizontal lines
leading to the vertical flow lines indicate the materials, whether purchased or worked during the
process. Parts are displayed when entering a vertical line for assembly or leaving a vertical line for
disassembly. Materials being disassembled or removed are represented by a horizontal material line
drawn to the right of the vertical flow line, while materials being assembled are shown by a horizontal
line drawn to the left of the vertical line.

In general, the DOP is constructed in such a way that the vertical and horizontal lines do not intersect.
If a crossing is necessary, conventional practice is used to show that there is no union, see figure:

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Time values are assigned to each operation and inspection, based on estimates or actual
measurements. The following Figure shows a DOP of an operation in the manufacture of telephone tables.

PROCESS OPERATIONS DIAGRAM

Manufacturing type 2834421 Telephone tables — current method
Part 2834421 Drawing no. SK2834421
Made by: B. W. N. 4-12-
Legs (4 reg.) Drawing 2834421-3 2 Frame (4 reg.) Drawing 2834421-2
Cover Drawing 2834421-1
1/2" x 1/2' x 16" white maple 1 1Z2" x 3" x 12 " yellow pine
1 1/2" x 14" x 1 4" white maple
.09 min
Saw to length ) Saw!
(o-1 2) .08 min (O-6 .13 min (o-1) Saw to length
approx. / length approx.
approx.
(o-13)
.30 “ .15 “
.23 “
Join two shores (o-7 ) Join a / edge (o-2) Join both ends

(o-14)
.32 " .30 “
Brush the
Brush to size (o-8 ) Brush to size .32 “ (o-3)
measure
.11 " (o-15) .10 *
Saw to final ) Saw to length / Saw to final
length (o-9 final
.16 " ( °"4 )
length
d. W: Check d. W: Check
Ins. 2 Check dimensions d. W: Ins. 1
Ins. 3 — dimensions dimensions

.28 min Sand everything .25 min Sand

h I Sand everything .50 min (0-5 ) everything-

2.00 min (0-11) Assemble 4

\_ stringers and
deck
8 x 11/2' Slot Wood Screws Part416412
Assemble
complete legs
Complete
inspection

Summary: Lacquer with spray gun #115-309

Apply a layer of
transparent
varnish.

The completed DOP helps the analyst visualize the current Sand completely

Event Number Time Apply lacquer

coat
Operations 20 17.58 minutes
Inspections Daily work Inspection
5
finished

method, in all its details, so that he can develop new and better procedures. Shows the effect that a
change in a given operation
will have on preceding and subsequent operations. It is common to achieve 30%
reductions in performance time by using operations analysis principles in conjunction with DOP. It is inevitable
that the construction of the diagram will suggest possibilities for improvement.

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PROCESS ACTIVITY DIAGRAM (DAP)
Also known as Process Analysis Diagram or Process Flow Diagram. This is a diagram that shows the
trajectory of a product or a procedure, indicating all the facts subject to examination by the
corresponding symbol. The DAP It can be done either to the material or process, to the operator or to
the machinery.

Activities represented in the DAP They are operation, inspection, transportation, delay, storage and
combined (operation-inspection).

DAP structure:

The DAP has the following parts:

1. Header: This section contains the main data of the operation under study. In this
case, the summary is part of the header.

2. Body or development.- It is the diagram itself. All activities are numbered and an "x" is placed in
the corresponding place. At the end the Y are joined with straight lines, obtaining the
coursegram.

The DAP It is used to eliminate unnecessary movements and analyze the process. There is a
conventional format for its preparation. The places assigned for times, distances and quantities in the
form should only be filled in where applicable.

DAP Analysis

In general, the DAP It contains much more detail than the operation process diagram. Therefore, it is
common that it does not apply to the entire assembly. It is used, in principle, for each component of
an assembly or system to obtain maximum savings in manufacturing or in procedures applicable to a
specific component or work sequence. The DAP It is especially valuable when recording hidden non-
productive costs, such as distances traveled, delays, and temporary storage. Once these non-
productive periods are detected, analysts can take measures to minimize them and, therefore, their
costs.

In addition to recording operations and inspections, these diagrams show all the movements and
storage of an item as it passes through the plant. Process flow diagrams, then, require additional
symbols than those used in operation process diagrams. A small arrow means a transport, which can
be defined as moving an object from one place to another, except when the movement is carried out
during the normal course of an operation or inspection. A capital D indicates a delay that occurs when
a part is not allowed to be processed immediately at the next workstation. An equilateral triangle
above a vertex means a storage, which happens when a part stops protected against unauthorized
movement. These five symbols constitute the standard set of process diagram symbols (ASME, 1972).

Commonly used process flow diagrams (PDAs) are of two types: product or material (see figures)
preparation of direct mail advertising and operational or perzona.
The product diagram provides details of the events that occur on a product or material, and the
operational diagram gives the details of how a person performs a sequence of operations.
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The same as the operation process diagram, this diagram is identified with a title, "process flow
diagram", and is accompanied by information including part number, its drawing, process description,
current and proposed method, and the name of the person who does it. Other data, such as floor,
building or department, diagram number, quantity, and cost may be valuable in fully identifying the
work to which the diagram relates.

For each process event, the analyst enters its description, marks the appropriate symbol and indicates
the process or delay times and the transport distances. Then connect the symbols of the successive
events with lines. The right column provides space for you to write comments or recommendations
for potential changes

To determine the distance moved, the analyst must accurately measure each movement with a tape
measure. It is common not to record movements of 5 feet ( 1.5 m) or less; However, it can be done if
the analyst believes that it materially affects the total cost of the method under study.

All delay and storage times must be included in the diagram. But it is not enough to simply indicate
that they occur. The longer a part spends in warehouse or is delayed, the greater the cost it
accumulates and the longer the customer will wait for its delivery. Therefore, it is important to know
how much time a part spends in a delay or storage. The most economical method of determining the
length of delays is to mark various parts with chalk indicating the exact time they were stored or
stopped. That section is then checked periodically to see when those parts return to production. With
a parallel sample in which the elapsed time and the average of those times are recorded, the analyst
can obtain values with sufficient accuracy.

The DAP, like the DOP, is not an end, it is only a means to achieve an end. This technique makes it
easy to eliminate or reduce hidden costs of a component. Because it clearly shows transportation,
delays and storage, the information it provides can lead to a reduction in both the quantity and
duration of these elements. Furthermore, by recording distances, the diagram has great value for
improving plant layout.

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FORMAT TO PREPARE THE DAP

ANALYTICAL COURSE SCHEDULE OPERATOR / MATERIAL / EQUIPMENT

DIAGRAM num: Sheet num: of SUMMARY

Object: ACTIVITY CURRENT PROPOSAL ECONOMY

Activity: Operation
Transportation
Method: CURRENT/PROPOSED
Waiting Inspection
Place: Storage
Distance
Operator(s): File number:
Time

Composed by: Date;

Cost Hand
Approved by: Date: of work Material
T SYMBOL
DESCRIPTION c O(m) Observations
(min) EIT
HER h d □ V

Total

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PROCESS ANALYSIS DIAGRAM – MATERIAL For the

preparation of direct mail advertising

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PROCESS ANALYSIS DIAGRAM – WORKER
For Lux field inspection

Location: Dorben Co. Summary

Activity; Inspector. LUX Oxygen Field Activity Current Proposed Savings
Date: 4-17-97 Operation
'7
T operator. Smith Analyst: R. Ruhf Transport 6
Delay
z
Check the appropriate method and type
Method: O 'Actual^ Proposed
Inspection 6
Type: (Material Worker Machine Storage
Comments: Time (rrin. 32.60

Distance (feet) 3/5

Cost

description of the activity Symbol Time Distance Recommended Method

(minutes)
(feet)
EI
Leave the vehicle, walk to the door, ring the doorbell d □ V 1.00 75 Talk to avoid delays
T
Wait, enter the cabin 0 d • V

Will walk tank

EI d □ 7 0.25 25

T • d • v
Disconnect Tank from Unit 0.35

ei • It is better to do e5to r iehtran walk to the

d 7 1.25
vehicle
Check for nicks, cracks in the coating, glass or missing parts.
th
Clean unit with cleaner and disinfect river mint rule => d □ V 2.25 This is done more effectively in the vehicle

>
Regrcóa: to the vehicle with an empty tank 0 d • 7 1.00 75

Open vehicle, place tarile in device and connect the machine d □ 7 1.75

•
Open valve; start writing d □ 7
0.25

Wait for the tank to fill 0 5 □ 7

12.00 Clean unit while filling

Check that the humidifier works well 0 eith

er d 7 BEAR Delete. Already done

Check pressure (indicator) 0 Y

d [ 7 02Ó
o
Check tank content (indicator) 0 eith
er d v 020

Return to the patient with a full tank 0 d □ V

110 100

Connect the full tank

• d □ 7 ‘.00

Check humidifier operation ei AN

D• d V 0,75

th
Wait for the patient to remove the nasal cannula or mask
0 • □ 7 2.00

Install naeva cannula or mask

• d □ 7
2.50
fait
Check flow with the patient 0 =
h
7 2.25

Set label with initial and date of insertion

•> d □ V 1.00 Do this during the lenad

Return to the vehicle 0 d □ 7 1.00 100

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STROKE DIAGRAM

This diagram is a graph that shows us the path of one or several products through a section, a
department or a plant.

This diagram must include a scale plan of the physical location under study. It is recommended to
include data such as: entrances, exits, passageways, columns, levels or floors of the plant, location of
machinery, workplace facilities, storage areas and administrative offices. To prepare it, it is necessary
to have previously made the process flow diagram for one or more products.

Steps to prepare a Route Diagram:

1. Create the process flow diagram (DAP).

2. Overlay the DAP on the plan, in such a way that the activity coincides with the physical place of
execution.

In the Route Diagram there may be lines crossing. The use of colors is recommended to represent the
path of the inputs to be used in the production process.

BIBLIOGRAPHY

• NIEBEL, Benjamin. Industrial Engineering, methods, standards and work design. Tenth Edition, 2001
• DÍAZ, Bertha and NORIEGA, Ma. Teresa. Techniques for the Study of Work. Editorial Fund of the University
of Lima, 1997.

PROBLEM N° 01

Case: WHEAT FLOUR "ANGEL"

The company Molinos El Quijote SA produces ANGEL brand wheat flour; The flour production process
consists of three stages: preparation or conditioning of wheat, milling and bagging.

It all begins by extracting the necessary amount of wheat from the storage hoppers to be processed,
according to the Production Order. Next, the wheat is subjected to a laboratory test to measure its
humidity and, according to the results obtained, determine the amount of water that should be
added. In order to avoid contamination as well as alteration in the color and flavor of! wheat, the
water is previously subjected to a purification process.

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After the humidification process, the wheat is sifted in order to separate foreign elements.
Subsequently, the first grinding is carried out, where the large shells are also separated. As a result of
this grinding, wheat is obtained in medium grains.

Next, the second grinding is carried out, from which small shells are released, thus obtaining
semolina. Finally, the third grinding is carried out where the flour is obtained, which is left to rest for
40 days so that it develops the optimal properties that will allow the products prepared from it to
acquire greater volume and, therefore, better performance. .

After resting, the flour is weighed while it is emptied into bags (50 kilos); The bags have previously
undergone quality control. The bag is then closed by sewing it with wick. During this operation, a label
that has previously been identified with the batch and bagging date is placed on the seam. The bag is
stacked on a stretcher for transport to the warehouse.

Prepare the Process Operations Diagram for the production of Angel Wheat Flour.

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Solution to Problem No. 1

DIAGRAM OF OPERATIONS OF THE PROCESS FOR THE PRODUCTION OF

“ANGEL” WHEAT FLOUR
cl b

-------------------

---------------------------------------

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CONTINENTAL

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PROBLEM N° 02

Case: BOUND NOTEBOOKS "NOTEBOOK"

The production process begins by taking the reel of white paper from the warehouse to the Pinomatic
machine, where the striping, cutting and folding of the paper is carried out, obtaining the so-called looms
(20 sheets of lined paper measuring 1,033 m and 32 cm, folded on the longest side).

Next, the looms are taken to the sewing table, where an operator, with a wick and a thick needle,
manually sews each loom on the side that was folded (8 minutes). Next to it is the table where the
reinforcements are glued; The reinforcement is a thick white paper that is placed on the long side of the
loom, using glue for gluing (4 minutes). At this station it is checked that the glue has not formed balloons
at the time of gluing. These looms are then placed on a rack, in rows of 100, and left to dry for
approximately 3 hours.

Subsequently, they are taken to the guillotine, where each loom is cut (10 minutes), obtaining five
booklets of 40 pages each.

The booklets are taken to the endpaper gluing table (first sheet of the bound notebook), in this operation
an endpaper is placed on five booklets together, using latex-based glue (12 minutes); While the gluing is
being carried out, its quality is verified. They are then taken on carts to shelves, where they will be dried
in the environment for a period of three days.

After three days, they are taken to the assembly table, where the notebook is bound, which consists of
placing the cover, previously prepared, on the five notebooks joined with the endpaper (5 minutes).
When gluing, check that it is even and there are no lumps or air balloons; This stage culminates with
pressing, an operation that consists of placing 20 notebooks in a press to set the binding.

Finally, the notebooks are taken to the packaging table, where with kraft paper, packages of 20
notebooks are assembled, which are secured with straw (4 minutes). The packages are then taken to the
warehouse for further distribution.

It is requested to prepare the Process Analysis Diagram and the Route Diagram.

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Solution Problem No. 02

DAP

ANALYTICAL COURSE SCHEDULE DPERARO-I MATERIAL / EQUIPMENT

DIAGRAM number 1 Sheet number: 1 SUMMARY
Object: Bound notebooks ACTIVITY CURRENT PROPOSAL ECONOMY
Operation 12
Activity Complete process
Transport 11
ACTUAUPROPOSED method Wait -
inspection 03
Place BOOK SA Storage 02 -----------
Operator(s): Vanos File number Distance ---------------- ------Yo
Time
Composed by: Juan Pérez Date: 06/06/00 Cost
Labour
Approved by: Peter Smith Date: 06/07/00 Material ---------------
DESCRIPTION
c D(m> T<mln) SYMBOL. -------------------- Observations
01 Coil of bond paper in the warehouse 1
_____________________________________________________________________________________________
02. The paper reel is transferred to the Pinomtic machine

03 The paper roll is scratched

04 The paper roll is cut 1 ••

05 The paper roll is bent 1 and, 20 looms were obtained

06 The looms are moved to the sewing table 20 p

20 8 •Yo
07 The sewing is done
08 Moved to the reinforcement gluing table

09 The reinforcements are stuck 20 4 22 With .

20 'D•
1O The bonding of reinforcements is inspected
1 1 The material is transferred to the loom racks 20
20 180 and(
12. The drying of the looms is carried out
13. The looms are moved to the guillotine 20 p
2Q 10 «( 100 tickets are obtained
14 The looms are cut

1 5 They move to the guard gluing table 100p

16 The endpapers stick 100 12 ---------------•and With color in groups of 6

1 7 Moved to the booklet shelves 100 90m,

18 The booklets dry out 100 4320 •(

19. Moves to the assembly table 100 or

100 10O ---------------------------= so place ••• lapes c/S notebooks
20. The notebooks are assembled

21. It goes to the presses 20

20 •((
22 The notebooks are pressed

23. Moves to the packaging tables »>

24 They are packaged 20 4 •

25 Moved to PT warehouse
1 5 3
26 Storing bound notebooks

Total 1 ______J._____________12 11 | - 1 03 1 02 |_________________________________________ 25

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Stroke diagram