The Psychology of Quality and More

A Toolbook for Quality Improvement and Problem Solving (contents)

Flowchart: Examples

The Quality Toolbook > Flowchart > Examples

When to use it | How to understand it | Example | How to use it | Practical variations

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Example

A product assembly team in a gaming machine manufacturer were looking for ways of building the product more efficiently. They broke down the assembly process into a set of Flowcharts, showing how sub-assemblies were made and then built into the final product. Analysis of the reel assembly process revealed two improvements:

1. The kit of parts was already checked by the kit assembly line, who were sometimes careless, as they knew the kit would be rechecked. The assembly line process was improved so the check here could be removed. This saved over two minutes per reel in checking, and up to fifteen minutes when the kit was faulty.
   
2. Fitting the reel band after the reel had been attached to the base was awkward. Fitting the band before the reel was attached to the base was more comfortable and saved about a minute per reel.

Other examples

• A management team uses a Flowchart to map and agree the actions in their strategic planning process. The resulting diagram helps them to achieve a clear agreement on the actions and their sequence
• A garage mechanic uses a Flowchart to check the sequence of actions in tuning engines with a complex new system. Pinned to the garage wall, he then regularly refers to it until he has learned it by heart. He also uses it to train both existing staff and new recruits.
• A restaurant team maps the sequence of actions taken in preparing a meal in order to spot inefficiencies. The result is a significant reduction in effort.

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