Page 55 - Six Sigma for electronics design and manufacturing

The Nature of Six Sigma and Its Connectivity to Other Quality Tools
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team members to understand the overall manufacturing processes
and their interactions, and were used as the basis for formulating a
new strategy for the production function of the company.
The DFD diagram in Figure 1.7 contains data stores, which are
named by acronyms particular to this manufacturing operation. Their
intent was to document the manufacturing process flows in general,
and not to specifically detail every existing operation and process. Al-
though no data dictionaries or process specifications were provided for
the current process, the reader can follow the information and data
flows through the different departments, and understand the com-
plexity and interconnection of the different systems involved in sched-
uling and manufacturing the product. When designing new manufac-
turing processes, it is advisable to create the data dictionaries and
process specifications to identify each procedure in as detailed a man-
ner as possible.
The data flow diagrams can be used as a quick reference to un-
derstand and follow the manufacturing system procedures and re-
quirements. They can lead to better management of the manufactur-
ing function and the data structure needed to support it. They
provide a visual representation of the connectivity of the different
departments, databases, and functions to be performed. The results
of using process mapping are well-managed and efficient operations
made possible by:
Eliminating redundant operations, which will become apparent
once the total process is visualized.
Improving the efficiency of existing operations by clearly identify-
ing the responsibilities of each and its relationship to other opera-
tions, as well as by providing the information necessary for correct-
ly performing its functions.
Better integration with outside activities and sharing of existing
resources rather than developing new ones, based on the descrip-
tion of the procedures and documentation of the current process.
Increasing data integrity by eliminating excess operations. More
accuracy will result when databases are well connected, consulted
more frequently, and used in more applications. With more focused
attention, data has a greater chance of being maintained correctly.
Process mapping methodologies could be very useful when new
processes and products are designed or improved to six sigma levels.
A good understanding of the system components and their interac-
tions is very beneficial in successfully achieving the goal of six sigma
quality for the entire enterprise.