Changeover Key Inspection Key Process Flow Diagram Part #

P=Product A=Automatic Customer Part #

T=Tooling M=Manual Product:
S=Software V=Visual Rev Date:
D=Dunnage Q=Quality Audit Prepared By:
L=Label Symbol Instructions

(KCC, QCC)
(KPC, QCI)
Changeover
Store/Get Significant Product Significant Process

Contain
Rework
Inspect

Scrap/
Operation Description Characteristics Characteristics

Class

Class
Move

Op-
Fab

Seq (Outputs) (Inputs)

A

Step 1

Step 2

Step 3

Step 4

Step 5

Step 6

Step 7

Step 8

Step 9
Step 10

Step 11

Step 12

Step 13

Step 14

Step 15

Step 16

Step 17

Product Line: XXX 305-7 Process Flow Diagram, rev. 02/08 1 of 6

Changeover Key Inspection Key Process Flow Diagram Part #
P=Product A=Automatic Customer Part #
T=Tooling M=Manual Product:
S=Software V=Visual Rev Date:
D=Dunnage Q=Quality Audit Prepared By:
L=Label Symbol Instructions

(KCC, QCC)
(KPC, QCI)
Changeover
Store/Get Significant Product Significant Process

Contain
Rework
Inspect

Scrap/
Operation Description Characteristics Characteristics

Class

Class
Move

Op-
Fab

Seq (Outputs) (Inputs)

Step 18

Step 19

Step 20

Step 21

Step 22

Step 23

Step 24

Step 25

Step 26

Step 27

Step 28

Step 29

Step 30

Product Line: XXX 305-7 Process Flow Diagram, rev. 02/08 2 of 6

Tips for Drawing Charts
The charts are drawn using Excel's Drawing Tools. You must have the drawing toolbar displayed in order to draw charts. If you don't see a toolbar with buttons
like "Draw" and "AutoShapes" etc, then click the View dropdown at the top of your screen, then click on "Toolbars", then ensure that the "Drawing" entry has a
checkmark next to it.

Do not add columns to your spreadsheet. Do not delete the graphic icons in row 9, or add or delete any rows above row
9. It is acceptable to add rows below row 9.
As you develop your Process Flow Diagram, you should place graphical icons in the appropriate column for each process step. Typically, there will only be one
icon per process step (one icon per row). Generally, you will probably find it easier to place all your icons BEFORE you start drawing lines, but this is not required.
Note that once you've placed icons and lines, Excel WILL keep them connected properly when you add and adjust rows within the body of your flow diagram.

General Methodology for Developing a PFD

The following general mechanism will help you to prepare PFD forms most easily.
1./ Sketch out the process flow, including rework and scrap or containment.
2./ List the operation sequence and operation description.
3./ For inspection process, list the items being inspected.
4./ Begin filling out the PFD forms using the techniques described on this page.
> Add the text description for all operations first, to help block out the form
> Add process symbols by using the "control-Z" mechanism described below. Use color to enhance clarity, but ensure it makes sense in B/W.
> Change the key letter in Inspection icons by following the instructions shown below.
> Add flow LINES after all icons are in place. Follow instructions below. For best results, use line weights of 0.75 points or greater.
> For rework items, show where the parts come from and where they return to the flow.
> For scrap items, show where the parts come from and if they are placed to a tote or reject chute.
5./ List the changeover items by utilizing the letter keys
6./ Complete the diagram by listing the KPCs or QCIs, KCCs, and Significant Product and Process Characteristics.
7./ Save early, Save often...

Placing, Removing, Coloring Chart Icons

To Place an Icon: to place a new icon, click in the cell in which it should appear (select the cell). Press and hold the Control (Ctrl) key on your keyboard, then
press and release the letter Z key. Then release the Control key. A copy of the appropriate icon will appear in the selected cell. Ctrl-Z places new icons

To Delete an Icon: To delete an icon, first delete all connecting lines attached to it. Then use the mouse to click in the center of the icon you wish to delete. You
should see little "selector squares" appear around the icon. When you see these squares, press and release the DELETE key on your keyboard.

To Change the Color of a Graphical Icon: use the mouse to right-click on the icon, then left-click on the "Format AutoShape" entry in the pop-up menu. Click
in the "Color" dropdown box near the top of the dialog box, select an appropriate color, then click on "OK". Remember that color is a useful tool for helping with
understanding, but MANY PEOPLE DO NOT HAVE ACCESS TO COLOR PRINTERS, so use it sparingly and make sure that the document is understandable
when printed in black and white. Note also that light colors (such as yellow) don't always show up well when printed on some laser printers.

To Change the Letter Key in an Inspection Icon: after you've placed the icon using the Ctrl-Z technique, click on the ICON itself, using the mouse. Hit the DEL
key to eliminate the letter, then retype the appropriate letter while the icon is still selected. Remember to use upper case letters for clarity.

Note: if you don't want to use the Control-Z shortcut, it is possible to use Excel's Copy/Paste mechanism to place icons in the operation columns. If you do so, it
is VERY IMPORTANT though that you copy the CELL, not just the GRAPHIC. Click IN THE CELL containing a graphic, but NOT ON THE GRAPHIC - when the
whole cell is selected, you may hit Edit/Copy, or Control-C to perform the copy operation.

Note: please to not drag and/or move graphical icons within the cells.

Drawing, Removing, and Formatting Connecting Lines

To Draw a Connecting Line: click on the "AutoShapes" button on the drawing toolbar. Click on the "Connectors" entry. You'll see a menu with several kinds of
connecting lines. The ones you want are the Elbow style connectors in the second row. The 3 options in that row select different options for arrowheads on the
ends of the line. Click on the button representing the flavor of line appropriate to your process flow.

Now move your cursor up to one of the graphic icons you wish to connect to. When you're hovering near it, several little blue dots will appear on the periphery of
the icon - these represent potential "connection points". Move the mouse over the connection point you wish to use, then depress the left button on your mouse.
Continue to hold the button while you drag the mouse towards the icon you want to connect to. When you get there, hover over the desired blue dot on THAT
icon, then release the button to create the line.

To Change the Arrows on the Ends of the Line: if you need to remove arrows or add arrows to either end of an already placed line, left-click on the line using
the mouse. Notice that the line gets little red boxes at the ends, and a little yellow diamond in the middle. When you see these, right-click with your mouse while
still keeping the cursor over the line. You'll see a flyup menu which has "Format Autoshapes" on it. Left-click on the "Format Autoshapes" entry and you'll see a
dialog box which has options for changing the arrows. The "Beginning" end of the line is the end which you drew first, the "Ending" end of the line is the other
end...

To Change the Line Style or Color: You can change the color and/or width of the lines, and make them dashed or solid by following the same procedure noted
above for Changing the Arrows. You'll see options for line style in the dialog box.

Remember that color is a useful tool for helping with understanding, but MANY PEOPLE DO NOT HAVE ACCESS TO COLOR PRINTERS, so use it sparingly
and make sure that the document is understandable when printed in black and white.

Line Widths: When you make lines (especially dashed ones) remember that not all printers are good at printing narrow lines. It is advisable to use line weights of
0.75 or more, especially for colored lines.

Adjusting Line Shapes: Excel usually picks a pretty good path for the line. You can adjust it a little bit by selecting the line (see above), then dragging the yellow
diamond to move the line. Sideways movements work pretty well, up-and-down movements are less helpful.

To Delete a line: To delete a line, left-click on the line using the mouse. Notice that the line gets little red boxes at the ends, and a little yellow diamond in the
middle. When you see these, hit the DELETE key on your keyboard. The line will go away.

202D-1-2-6 rev. 06/09

268F1 - (Revised 11JA02)

Changeover Key Inspection Key Process Flow Diagram Part # 123456789

P=Product A=Automatic Customer Part # 987654321
T=Tooling M=Manual Product: Example PFD
S=Software V=Visual Rev Date: 12-Dec-01
D=Dunnage Q=Quality Audit Prepared By:
L=Label Symbol Instructions

(KCC, QCC)
(KPC, QCI)
Changeover
Store/Get
Significant Product Significant Process

Contain
Rework
Inspect

Scrap/
Operation Description Characteristics Characteristics

Class

Class
Move
Op-

Fab
Seq. (Outputs) (Inputs)
A

05-1 P Communication information of parts

to be run to entire cell

05-2 P Stock w/cyl attach machine with

components and grease

05-3 Get & Load screws into feed bowl

(Setup function)

05-4 Get & Load 5 gallon pail of grease to

machine

05-5 A T Verify correct setup of equipment

V S
P

10-1 P Get Wheel Cylinder

10-2 T Load Wheel Cylinder Into Fixture of Correct wheel cylinder - delta
four (4) position dial machine has scallops at tennon, epsilon
has slotted tennon, gmt355
has scallops and is larger in
length

10-3 P Get Backing Plate

10-4 T Load Backing Plate Into Fixture Correct backing plate - delta
and epsilon same, J-car
different height of mounting
surface and mounting hole
shift pattern
10-5 P Get Plugs

10-6 Load Plugs into tooling

10-7 S Auto Install Plugs Plugs fully inserted and seated

T into slots in backing plate

10-8 A Inspect Wcyl for: Wheel cylinders purchased

S Correct Part with wheel cylinders oriented -
Presence of port protector double check to protect the
T Orientation of pistons customer
10-9 Index Machine

10-10 T Feed and Torque 2 screws QCI-1 Torque QCC-1 RPM, Target torque
(Skip if status is bad)

10-11 A T Auto inspect for torque and angle

(Skip if status is bad)

10-12 Index Machine

10-13 T Apply grease to shoe pads Grease on shoe pads - thin no air in system
(Skip if status is bad) film

10-14 A Inspect Backing Plate Assembly for:

T Plugs present and seated
Two (2) screws present
(Skip if status is bad)

10-15 Index Machine

10-16 Auto identify part as unique part with

2d Id Matrix

10-17 A Verify legibility of 2d ID matrix code

10-18 T Auto unload accepted parts to chute

10-19 T Auto unload rejected parts to reject

chute

10-20 Move rejected parts to teardown

bench

10-21 Teardown all rejects

10-22 Scrap screws

10-23 M Inspect backing plate for no grease

10-24 P Reintroduce plugs, backing plate and

wheel cylinder to correct component
stock
10-25 Operator Moves backing plate
assembly to Drum brake assembly

Form 202D-1-2-7
file name: 424450831.xls Page: 4 of 6
rev. 06/09
 PROCESS FLOW CHART CHECKLIST
Cooper Bussmann Part Number ________________________

Comment / Action Person

Question Yes No Due Date
Required Responsible
1 Does the flow chart illustrate the
sequence of production and
inspection stations?
2 Were all appropriate FMEA's
(SFMEA, DFMEA) available and used
as aids to develop the process flow
chart?
3 Is the flow chart keyed to product and
process checks in the control plan?

4 Does the flow chart describe how the

product will move, i.e., roller
conveyor, slide containers, etc.?
5 Has the pull system/optimization been
considered for this process?
6 Have provisions been made to
identify and inspect reworked product
before being used?
7 Does all Process Steps / Operations
match and linked to the Control Plan
and PFEMA, sequence, quantity of
steps and operation name?

8 Have potential quality problems due

to handling and outside processing
been identified and corrected?

Prepared By: Revision Date

Form 202D-1-2-8 rev. 06/09

Form 202D-1-2-8 rev. 06/09