1. What is a Process Flow Chart?
A Process Flow Chart is a visual representation of the sequence of steps followed to manufacture a product or complete a process, from the starting point to the final stage.
For example, in UPVC Hollow Sheet, UPVC Hollow Section, WPC Sheet, and WPC Door Frame manufacturing, the process flow chart shows how material moves from the Raw Material Store to the Material Dispatch Section.
2. Main Parts of a Process Flow Chart
1. Start / End Symbol
An oval represents the beginning or end of a process.
2. Process Step
A rectangle represents an activity or operation, such as Compounding or Extrusion.
3. Decision Point
A diamond represents a decision, such as whether a product meets the quality requirements (Pass/Fail).
4. Flow Lines / Arrows
Arrows indicate the direction and sequence of the process.
5. Input / Output
A parallelogram can represent material input, information input, or a process output.
For a simple manufacturing process flow chart, the essential elements are usually process steps and arrows. Decision points and other symbols are included when required.
3. Example: Your UPVC / WPC Manufacturing Process
Raw Material Store
Compounding Section
Extrusion Section
HSP Section
Printing Section
Wrapping
Packing
Finished Goods (FG) Yard
Material Dispatch
4. Why is a Process Flow Chart Needed?
| Purpose | Benefit |
|---|---|
| Process clarity | Everyone understands the sequence of operations. |
| Department coordination | Improves coordination between Stores, Production, Quality, Packing, and Dispatch. |
| Quality control | Helps identify where inspections and quality checks are required. |
| Training | Makes it easier to train new operators and employees. |
| Problem-solving | Helps locate the stage where defects or process issues may occur. |
| Standardization | Supports consistent working methods and documented procedures. |
| Audit compliance | Provides documented evidence of process understanding and control when used within the QMS. |
5. Process Flow Chart vs. SOP
- Process Flow Chart: Shows what happens and in which sequence.
- SOP (Standard Operating Procedure): Explains how to perform each activity, including responsibilities, parameters, methods, and safety precautions.
- Work Instruction (WI): Gives detailed instructions for a specific task or operation.
Recommendation for your Quality Department: Maintain the process flow chart as a controlled document, with a document number, revision number, effective date, and approval. Use it alongside the relevant SOPs and inspection plans. A flow chart supports an ISO 9001 quality management system, but the chart alone does not establish compliance.