PROCESS VISUALIZATION &
PROCESS WRITING
“ Planning the Right Process before Manufacturing”
BY: GAURAV BHARDWAJ
TRAINING OBJECTIVES
▪ Understand process visualization.
▪ Understand process writing.
▪ Develop logical manufacturing sequences.
▪ Select suitable machine and fixtures.
▪ Identify quality check points.
▪ Reduce errors and rework.
▪ Improve productivity and communication.
INTRODUCTION
If a new engineer joins today, how will he understand the job?
▪ By watching someone ?
▪ By Reading document ?
▪ By looking at drawings ?
WHAT IS PROCESS VISUALIZATION
“Process Visualization” means
seeing the complete manufacturing
process before production starts.
Definition: Process visualization is the ability to mentally map and
understand every stage of manufacturing before the first operation
begins.
PROCESS VISUALIZATION
It involves answering questions such as:
▪ What activity will be performed?
▪ In what sequence?
▪ Who will perform the activity?
▪ What resources required?
▪ What quality checks needed?
▪ What risks may arise?
WHY…..?
Why is process visualization important?
Without process visualization:
▪ Unclear Responsibilities.
▪ Incorrect operation sequence.
▪ Production delays.
▪ Material Shortage.
▪ Rework
▪ Quality issues.
▪ Poor coordination.
▪ Increased manufacturing cost.
WHY…..?
Why is process visualization important?
With process visualization:
▪ Better Planning
▪ Smooth workflow
▪ Reduce waste
▪ Improved communication
▪ Better quality
▪ Faster delivery
▪ Higher customer satisfaction
MANUFACTURING PROCESS FLOW
Customer Drawing Process Material Material
Requirement Review Planning Procurement Inspection
Surface
Quality Assembly (If
Fabrication Machining Treatment /
Inspection applicable)
Painting
Final
Packing Dispatch
Inspection
ELEMENTS OF PROCESS VISUALIZATION
A Manufacturing Engineer should visualize:
Product Resources Manpower Quality Safety
Size Machines Operators Inspection stages Hazards
Weight Equipment's Welders Customer Req. PPE
Material Tools Inspectors Acceptance Criteria Safe Work Practices
Function Fixtures Supervisors
Measuring Inst.
WHAT IS PROCESS WRITING ?
“Process Writing” means documenting every manufacturing step clearly so anyone
can perform the same operation.
It is a systematic documentation of manufacturing activities so that every person
understands:
▪ What to do
▪ When to do
▪ How to do
▪ Who is responsible
▪ What quality requirements must be met
It creates a standard method that can be repeated consistently.
COMPONENTS OF GOOD PROCESS SHEET
▪ Operation Number
▪ Activity description
▪ Department
▪ Machine / Equipment
▪ Tools / Consumables
▪ Quality Checkpoints
▪ Acceptance criteria
▪ Safety requirement
▪ Estimated Time
▪ responsibility
EXAMPLE PROCESS SHEET
Operation Activity Department Inspection
10 Drawing Review Engineering / Planning Approved Drawing
20 Material Receipt Stores Material Verification
30 Cutting Fabrication Dimensional Check
40 Fit-up Fabrication Alignment Check
50 Welding Fabrication NDT / UT / Visual
60 Machining Machine Shop Dimensional Check
70 Surface Preparation Painting Surface Cleanliness
80 Painting Painting DFT Check
90 Final Inspection Quality Inspection Report
100 Packing & Dispatch Dispatch Customer Documentation
PRINCIPLES OF GOOD PROCESS WRITING
What makes a Good Manufacturing Process?
A Good Manufacturing process should be:
Clear : Instruction should be simple and easy to understand.
Example: prepare the component properly
Cut the plate to 1200 x 800 mm as per Drawing no. ABC-101/Rev B
PRINCIPLES OF GOOD PROCESS WRITING
What makes a Good Manufacturing Process?
A Good Manufacturing process should be:
Traceable : Every Process should Identify:
▪ Drawing Number
▪ Revision Number
▪ Process Number
▪ Inspector
▪ Date
▪ Operator
PRINCIPLES OF GOOD PROCESS WRITING
Poor Process Writing Good Process Writing
Cut Material Cut IS2062 E250 Plate to Specified Size as per
Drawing. 1291 Rev. B
Weld Component Weld using approved WPS. Inspect root pass
before completion.
Machine Part Machine Mounting face and bore as per
drawing tolerance.
Inspect Job Verify dimension as per bauble drawing and
record result against specified size.
Paint Product Clean Surface, apply primer and finish coat, Ral
No. & paint specification.
IMPORTANCE
It helps to determine:
▪ Resource availability
▪ Material readiness
▪ Machine allocation
▪ Sequence of operations
▪ Inspection points
▪ Delivery schedule.
▪ Quality Check points
▪ Inspection methods
RISK IDENTIFICATION
It helps to minimize the risks include:
❖Wrong material
❖Incorrect drawings
❖Process deviations
❖Welding distortion
❖Machining errors
❖Inspection omissions
❖Handling damage
❖Late material Supply
❖Poor communication
BEST PRACTICES
➢ Understand requirements.
➢ Study drawings carefully.
➢ Involve all relevant departments.
➢ Plan activities in the correct sequence.
➢ Define quality checkpoints.
➢ Follow standard procedures.
➢ Communicate effectively.
➢ Review the process before production starts.
PRACTICAL EXERCISE TO DO……….
Take any product drawing………..
❖Visualize the complete manufacturing process.
❖Identify all departments involved
❖Prepare the manufacturing sequence
❖Write a simple process sheet
❖Identify quality check points
❖Identify possible risks and improvements.
Present it here in next part of this training…………………..
KEY TAKEAWAYS
Visualization Process Good Team Quality must Every
improves writing Planning coordination be planned, department
decision- standardizes minimize improves not just contributes to
making. work. rework. productivity. inspected. customer
satisfaction.
CONCLUSION
“Manufacturing excellence” is not achieved by one department alone. It is the result
of effective planning, clear process visualization, accurate process writing,
disciplined execution, continuous quality control, and strong teamwork.
A well-planned process transforms customer requirements into a quality product
delivered safely, efficiently and on time.
THANKYOU