Process Modeling
Contents:
1. Introduction and Objective
2. Process modeling methodologies applied
3. Process model in CIMpgr
4. Main Process
5. Collaboration with companies
6. More collaboration
7. Process descriptions
8. Data Dictionaries
9. Panorama Navigation Map
10.Invent and manage
11.Summary
12.References
1. Introduction and Objective
A&P eco-MHE is a private company which manufactures automated Omni – directional forklifts. We provide a
wide range of customization and material handling solutions to customers globally. The company uses
mecanum wheels to give Omni directional mobility to a lift truck. This allows normal forward and backward
motions like the conventional wheel, but also provides sideways motion and rotation about it center of gravity.
The parts used in the assembly of each forklift are interchangeable. Our cutting edge technology ensures high
efficiency and quality by obtaining high mobile accuracy and sustainable engineering. We also provide onsite
training sessions for operating the forklifts along with maintenance service.
Objectives
A&P Eco – MHE concentrates on developing the product at the first rather than considering rework. Quality
assurance and constant improvements in terms of functional requirements and customer satisfaction is the main
concern of A&P Eco-MHE. With a TQM business approach A&P understands the need of process modeling
which exhibits working of the company similar to a system and provides analysis towards efficient ways to
process and design forklifts focusing on sustainability.
Quality Objectives:
· Use of process modeling in order to achieve efficiency over each process operation with proper allocation of resources taking into consideration control factors, inputs and outputs required for each task.
· Exercise a set of methodologies to manufacture a quality product at the first attempt to save rework.
· Observe methods and processes which will ensure optimum use of raw materials.
· Use of most efficient processes and machinery to create a sustainable product along with sustainable environment.
2. Process Modeling Methodologies Applied:
Process modeling at A&P Eco-MHE is based on CIMpgr proposed by Paul G. Ranky. This method complies with
U.S. initiated, international standard object-oriented UML (Unified Modeling Language) and the European CIM-
OSA standard CIM reference architecture. This modeling process makes use of graphics and models to illustrate
the object to object relationship which can help visual understanding of the relationship between processes and
the outcomes of each process and the inputs required. CIMpgr enables the user to breakdown the parent process
into smaller child processes identifying the information such as inputs, outputs, resources and controlling factors
for each process. This model will help A&P Eco-MHE in identifying the most important and urgent tasks from a
group of routine tasks.
3. Process Model:
· CIMpgr method is well tested for integrated methods, tools and technologies for the purpose of analyzing,
specifying, designing, implementing, operating, maintaining all the process.
· Therefore adopting this method A&P will achieve its goals with accordance to PAT; a system for
designing, analyzing, and controlling manufacturing through timely measurements (i.e., during processing)
of critical quality and performance attributes of raw and in-process materials and processes with the goal
of ensuring final product quality.
· The process is broken down into many layers depending upon the need or importance of the process in to
total outcome. A&P has represented three layers of the CIMpgr. Layer 0 is the parent layer while layers 1
and 2 are the child layers.
Layer 0:
This process diagram describes the Global view of all processes implemented in A & P Eco-MHE. Layer 0, is
the parent layer and encompasses all processes and activities for the project. It shows the inputs, outputs,
constraints and the Resources that are necessary or implemented. The inputs are termed from I1A0 to I4A0,
outputs O1A0 to O5A0, constraints C1A0 to C7A0 and resources R1A0 to R6A0.This model efficiently shows
the goals of a business and set of inputs which would help produce the output with certain constraints and
resources available.
Layer 1:
Layer 1 is a child layer and helps break down the parent into smaller fragment with details related to each task
in the business. Layer 1 of A&P eco-MHE consists of the processes such as customer requirements
&manufacturing analysis, product design, manufacturing and assembly, quality control & testing and marketing,
sales & services. This layer allows the specific details such as information flow, material flow, allocation of
human resources and allocation of finance. This will allow each department to interact with each other and
identify the inputs required from other departments and outputs required to deliver to other departments under
the set of constraints and resources allocated to each department. This model allows data flow in a detailed
fashion and thus help managers keep projects on track.
Layer 2:
Layer 2 shows the required stages during quality control and testing in order to achieve the quality standards
promised to the customers. A4 stage also includes testing for functional requirements and safety testing and
thus is integrated with quality control. This stage is considered crucial in order to obtain data to propose
changes in manufacturing and assembly process in order to meet the quality standards and customer
requirements.
4. Main Process Related to TQM:
A&P observes good strict TQM principles and it is evident from the integration of the process model which always
strives hard towards customer requirements and customer defined quality. The process starts from acquiring
customer requirements and ends with satisfaction of the customer with less harm to the environment. The
integrated TQM system is always driven with conformance of customer specifications constraint. The process
concentrates on conformance of performance, reliability, durability, serviceability and sustainability. The company
mainly concentrates on process management where in quality is built into the process and sources of quality
problems are identified and corrected at right the right time. The company has applied robotic arms on the shop
floor in order to avoid errors. Robots arms are also applied to tasks which are time consuming but may cause
errors such as pick and drop task. The company integrates it TQM with the collaborating companies in order to
identify, understand and manage contributions towards effectiveness and efficiency. Considerable cost is
invested by A&P with a support from the collaborating companies for R&D. Data and information obtained from
R&D is integrated among all the departments of all the companies in order to make change effective which counts
towards continuous improvement.
5. Collaboration With Companies:
A. Quality Carbide tools:
QCT designs and manufactures carbide tools. The products include wide range carbide drills, reamers,
countersinks, end mills, carbide de-burring tools and all the standard tools. QCT is committed to customer
satisfaction and has a quality policy of continual quality improvement. QCT is ISO 9001:2008 certified company.
QCT will be the key supplier of high speed cutting tools. QCT along with sunnen: above and beyond honing would
provide efficient solutions in cutting process and related automation. QCT and sunnen would work in an integrated
environment where in sunnen would provide solutions to machinery and QCT will provide appropriate tools.
B. Sunnen: Above and Beyond honing:
Sunnen is a global leader in manufacturing and distribution of bore sizing and finishing equipment, tooling and
abrasives. They manufacture machinery as well as the honing tools which are solutions to almost all sizes of
bore. The brushless AC motors used in the forklifts along with the drive system require close tolerances and thus
high level of finishing is mandatory. Sunnen provides high end customized finishing systems. QCT manufactures
carbid tools as per the tool requirements of sunnen machinery.
C. Rexroth Bosch Group:
Bosch Rexroth is one of the world’s leading specialists in field of drive and control technologies. They develop,
produce and sell components and systems in the technology fields of electric drives and controls, industrial
hydraulics, mobile hydraulics, assembly technologies and pneumatics. The company provides technical and
design support for hydraulics and electric drives and controls required in the forklifts. Rexroth provides the
specifications for each related components and QCT along with sunnen support manufacturing mechanical
components for the hydraulic systems and electric drives & controls.
D. The Numina Group:
The numina group provides smarter and faster automation to material handling. Their products include: Conveyor
Systems, Pick Zone Carton and Tote Routing, Pick or Put to Light-Voice Pick, storage automation. The Pick or Put
to Light-Voice Pick technology of numina group is used in A&P for the purpose of inventory transportation. Thus
numina group plays a key role in inventory control by reducing to transportation time on the shop floor. Numina
group provides conveyors systems required on the shop floor of A&P, along with maintenance and servicing. PLC
control systems installed in the forklifts is another input for A&P from the numina group.
6. More Collaboration:
The relationship with collaborating companies is never one way. A&P Eco – MHE will supply material handling
equipments to the collaborating companies. A&P strives hard in order to spread the word “sustainability” amongst
the collaborating companies. A&P with an eco friendly product induces sustainability in customer’s business.
A&P will observe strict TQM principles and concentrate use of materials which are reusable. A&P expects all the
collaborating companies to understand these goals and work with sustainability and quality from a business point
of view. The spare parts required for the forklifts such as hydraulic system, PLCs, drives and controls are
engineering of the collaborating companies and thus A&P would expect these companies to provide service for
these parts after the sales. This will also help the companies produce profit and maintain a status in the market.
7. Process Descriptions (PDs):
· TQM – A business approach with a strict focus on quality of every process in the operating system. Every staff
member is committed to maintain high standards of work in every aspect of companies operation. A well integrated
TQM among the collaborating companies and the departments with a promise towards customer defined quality
and continuous improvement.
· Green – A concept which ensures that process and products are not hazardous to the environment and reduced
use of oils.
· Sustainability – A concept that visualizes products or services that can be seen reliable and valuable for
generation along with improvement in the future. Manufacturing sustainability is achieved by use of renewable
material and optimum material utilization which ultimately reduces waste generation. The product sustainability is
obtained by use of electric motors instead of fuel consuming IC engines.
· Quality – The Company is driven by principles which satisfy customer defined quality. An overall effectiveness of
the product is obtained when it is utilized in the highest standard of use.
8. Data Dictionaries:
1. ANSI: American National Standards Institute. The American National Standards Institute (ANSI) coordinates the
development and use of voluntary consensus standards in the United States and represents the needs and views of
U.S. stakeholders in standardization forums around the globe
2. Database: An integrated information management system typically consisting of data, procedures, files, relations,
menus, etc. which allows one to store, retrieve and manipulate information.
3. Data dictionary: A repository of definitions of the purpose and structure of all data types used in data flow
diagrams, in process specification, or in the data dictionary itself.
4. Process: A process can be defined as the transformation of one or more inputs (data, raw materials, customer
requests, etc.) into outputs (processed data, processed materials, satisfied customers: as a service, etc.)
5. Input/ Output, or I/O: The data entering the system to be processed is the input and
6. Resource: A resource is a source or supply from which benefit is produced.
7. Constraint: Constraint is an element factor or a subsystem that works as a bottleneck.
8. Transformation: The transformation involves the addition or creation of value, typically by processing data,
improving on cycle time, reducing failure rate, increasing robustness, reducing cost, changing place, changing form, or
shape.
9. System integration: An implementation and/or testing strategy and methodology in which all the subsystems of a
system are brought together at once to be tested and debugged step-by-step.
10. Testing: A means of determining the capability of an item to meet specified requirements by subjecting the item to
a set of physical, chemical, environmental, or operating conditions
11. Total Quality Management (TQM): It is a participative management style that stresses total staff commitment to
"customer" satisfaction. It is a holistic approach to managing complex organizations and replaces top-down
management with decentralized customer-driven decision making. TQM is an integrated management system for
creating and implementing a continuous improvement process, eventually producing results that exceed customer
expectations. It is based on the assumption that 90 percent of problems are a result of process, not employees.
12. Safety Standards: Safety standards are standards designed to ensure the safety of products, activities or
processes, etc. They may be advisory or compulsory and are normally laid down by an advisory or regulatory body
that may be either voluntary or statutory.
13. ISO Standards: The International Organization for Standardization is an international-standard setting body
composed of representatives from various national standards organizations
14. Quality: The level of performance of a product, a service, a production process or lot, measured in terms of
specified requirements.
15. Quality assurance: All the stated and planned systematic actions necessary to provide adequate confidence that
a product or service will satisfy given requirements for quality.
16. Quality Control: It is the effort of an entire enterprise to develop, design, manufacture, inspect, market and service
products that will satisfy the customers at the time of purchase and give them satisfaction for a long time after
purchase.
17. Quality Function Deployment (QFD): An integrated engineering planning tool, a requirements analysis tool that
can be applied to any product design process.
18. Verification: The act of reviewing, inspecting, testing, checking, auditing, or otherwise establishing and
documenting whether items, processes, services, or documents conform to specified requirements.
19. CIMpgr: A graphical method for modelling a system. (note: the modelling for this assignment is done with the help
of Microsoft Visio 2003).
20. ISO9001: is a family of standards for quality management systems. ISO 9000 is maintained by ISO, the
International Organization for standardization and is administered by accreditation and certification bodies.
21. Green: A concept which ensures that process and products are not hazardous to the environment and reduced
use of oils.
22. Sustainability: Is also the foundation of our company. A concept that visualizes products or services that can be
seen reliable and valuable for generation in furture.
9. Panorama Navigation Map:
This tool can be effectively used in order to obtain a overview of the whole system and describe each process in
detail in a manufacturing plant. Taking 360 degree videos of the A&P Eco – Material handling equipments would
help in train sessions of the employees and help them deliver with a mark of quality. It can prove a vital way of
training people to work in hazardous environments. It can also be implemented in order to give customers an
overview of the organization system through well explanatory images and videos. This technology can also prove
effective in order to implement improvements and the related analysis. As it gives visual contents it produces a
creative path for the engineers to work on improvement techniques. This technology on implementation can help
observe the material flow and will surely help in the discrete event and continuous flow simulation. A&P aims to
utilize this technology in order to achieve its goal of least material handling and increase the productivity in order
to full fill the customer defined quality and functional requirements.
10. Invent And Manage:
A&P invests a considerable amount of it profit in R&D. The focus is on the process improvement and
product design. With the use of CIMpgr modeling process sustainability is under improvement on project
basis on a continuous run. A&P motivates employees in order to focus on these goals with a green
approach. There are training sessions and motivational campus throughout the year which helps the
employees to gain an upper hand on technology and it management with an aim: Quality. After every
successful improvement project change management flows through the entire system and employees in
our company are trained in such a fashion that the thinking “change is inevitable” is nurtured deeply.
A&P recently upgraded the lighting system with more efficient and less energy consuming bulbs and tube
lights. The numina group is working hard in order to have an efficient hand on inventory control. The
numina group is implementing storage/retrieval system which is completely automated and has a good
warehouse control.
12. Summary:
The CIMpgr model helps efficient hand over each process and the proper inputs are implemented to get desired outputs
within the constraints and resources available. This model helps the business with optimum and appropriate use of
resources. The relationships between process and the flow of material as well as data can be analyzed effectively. The
TQM techniques are applied and integrated in the system with good feedback system that maintains quality data for
future use.
We, A&P Eco – Material handling equipments have adapted an operating system with a goal to satisfy customer
defined quality and functional requirements with an optimal cost. The four collaborating companies help A&P to
achieve a good workflow and quality which leads to customer satisfaction beyond the customer expectations. The
CIMpgr model of A&P eco-MHE helps to identify problems and keep problem solving on track and thus continuous
improvement is obtained.
14. References:
1. Paul G. Ranky, IE673 Total Quality Management eLearning Pack ID: IE673-Spring 2012-95-66
2. http://www.cimwareukandusa.com/All-Green/Ranky-GreenEngineering.html
3. http://www.cimwareukandusa.com/CIMpgr1.html.
5. http://www.boschrexroth.com
