Order Management Flowchart (January 1, 2002)

Customer
sends PO.

Yes
Is there a Receive
Follow process for
new drawing Drawings Chart.
receiving drawings.
with the PO?

No

No
Was written Contact customer for written
confirmation confirmation prior to beginning, unless
sent? otherwise specified by management.

Yes

Was PO No
Contact customer to obtain
information missing information.
complete?

Yes

No
Do price and No
Contact Continue
quantity on Wait for
Management for with new
PO match new PO.
further instructions. information?
quote?

Yes
Yes

Confirm PO to
customer according to
customer’s wishes.

Enter PO in database
as a Work Order.

60
 Is the Yes Follow the
assembly a procedures for a New assembly
new one? “new assembly” Chart

No

No
Is the latest Contact customer
drawing for latest drawing.
available?

Yes

Are changes Yes

Have appropriate Document Change
required to personnel review changes on documents.
D&I or assembly and note form
BOM? changes.

No Make a sample
according to
changed documents.

“New Assembly” New Assembly

Verify sample against
Process rejoins Chart.
Main flow. customer drawing

Record results
on form.
No
Is a test Order parts for a test
fixture fixture (mating
available? connectors). Yes
Are
changes
Yes required?

No
Print a “Materials Required”
Report and use the BOM to
determine the materials that
must be ordered.

Make proper scrap allowances.

61
 Search inventory for
existing stock.

Check the vendor approvals.

Obtain material pricing

from vendors.

No Re-quote assembly
Does current Contact management for for customer. Re-
pricing match instructions on re-quoting start Order process
the pricing in or proceeding. if customer accepts
quote?
new quote.

Yes
Continue.

Order materials from

vendors.

Document PO’s in
database and print
PO’s for vendors.

Adjust inventory levels

for order (subtract
requirements).

No
Is a labor
Obtain a labor estimate Enter labor estimate
estimate
from management. in database.
available?

Yes

Schedule the WO in the

places required using the
labor estimate as a guide.
62
 Receive materials
as they arrive.

Inspect material according to

incoming material standards.

No Follow “RMA”
Does procedures to
material return material.
conform?

Yes

Update inventory levels to account for received material.

Does Invoice Contact vendor for an Apprise

price match quote explanation of Management of
& PO price? pricing discrepancy. the explanation.

Follow Management
Print all documentation instructions for replying
for WO jacket. to vendor and dealing
with the invoice.

Decide the type of

production for the order:
small, large, or special.

Issue WO to floor when

sufficient materials are
available to begin.
Receiving
additional
materials.
Production teams draw
material from inventory.

Document material
draw in appropriate
database.

63
 Yes
Are more
Receive materials
materials
as specified above
to arrive?
as they arrive.

No

Prepare cable according to

Assembly Instructions.

Inspect cable
according to standards.

Document
inspection results
in database.

No
Does
material Sort material to remove
pass non-conforming material
inspection? according to Sort
procedures (See Chart).

Yes

Terminate according to
Assembly Instructions.

Inspect material
according to standards.

Document
inspection results
in database.

No
Does
material Sort material to remove
pass non-conforming material
inspection? according to Sort
procedures (See Chart).

Yes 64
Complete according to
Assembly Instructions.

Perform electrical tests

according to Instructions.

Document electrical
inspection results in
database.

No
Do cables
pass Sort material to remove
inspection? non-conforming material
according to Sort
procedures (See Chart).

Yes

Perform mechanical tests

according to Instructions.

Document mechanical
inspection results in
database.

No
Do cables
pass Sort material to remove
inspection? non-conforming material
according to Sort
procedures (See Chart).

Yes

Count the cable

assemblies to ship.

65
 Report count to office.

Make a packing slip for

the shipment.

Pack according to
shipping standards
and Instructions.

Enter final record in

shipping log.

Reconcile shipping
log and packing slip

Calculate shipping and

handling costs and enter
them in database.

Print invoices and mail

them to customers.
Keep one copy for
records.

Is order No
finished (no Repeat process for
more each additional release.
releases)?

Yes

Return unused inventory.

Calculate scrap from inventory

draw and return records.

66
 Adjust inventory levels
from scrap calculations.

Make closing entries for

WO in database.

Finalize and
collect WO
documentation.

Submit WO jacket to
management for review
and approval.

Follow up with
customer if invoice not
paid in forty days.

Yes Sort material to

Customer Log return in Determine separate non-
returns? database. problem(s). conforming
material according
No to steps in Sort
Chart.

End

Rework or replace
material based on
Return material Production, Inspection,
to customer. and Management
Document
instructions.
changes.

Yes
Follow change CAR
documentatio Follow customer
procedures for
n required? CAR instructions.
previously produced
assemblies.

Yes No

Are D&I or Document

BOM changes return and
required? remedy.
No

67
 New Assembly Flowchart (January 1, 2002)

From Main
Flowchart for New
Assemblies.

Review customer drawings

and documentation to
develop a BOM.

Verify the BOM.

No.
Is BOM Change BOM as
correct? required.

Yes.

Enter BOM
in the
database.

Use BOM to
purchase
materials.

Use customer
information to create an
internal drawing and
instruction set (D&I).
Print new
D&I.

Make a sample cable

assembly using D&I.

Inspect the sample

assembly against the
customer’s drawing.

68
 No.

Is the
sample Determine the Document Change D&I.
correct? changes required. changes on a
Change Form.

Yes.

No.

Is proper
tooling Inform Management and
available? obtain proper tooling.

Yes.

Return to Main
Flowchart for test
fixture procedures.

69
 Drawing Record Flowchart (January 2, 2002).

Customer sends a
drawing of a cable
assembly (every time).

The first drawing entered in

the database for each new
Enter the P/N,
assembly should be the one
date, drawing
accompanying the first
date, and Rev.
quote or RFQ.
level in database.

Sort the database for

all entries pertaining to
this P/N.

No.
Has the date or Indicate “No changes”
Rev. level in the database record File drawing
changed with the and continue to use and stop.
present drawing? present set D&I.

Yes.

Determine the differences, if

any, between the present
drawings and the previous set.

No.
Are there
any
changes?

Yes.

Note the changes between

the drawings.

70
 Yes.
Are the changes
significant enough to Submit the new drawings
change the price of the to Management to re-
assembly (Consult quote the assembly.
Management if Submit quote to customer.
necessary)?

No.

Record the changes

required on a Change
Form and submit for
approval.

Change D&I according

to change form.

Produce a new
D&I and destroy
old D&I.

Follow the procedures for a

“Changed” assembly for the
next PO (samples, etc.).

Note the changes

made in the database
for future reference.

Use these records to

determine whether the
most current version of
D&I are being used.

File drawing and stop.

71
 Re-Quote Flowchart (January 2, 2002)
[When prices no longer account for costs]

Assembly price no longer reflects

material or labor costs and
Management deems it necessary
to re-quote assembly to customer.

Obtain pricing
data for
assembly’s
BOM and labor
requirements.

Inform customer that their

order is on hold until the
assembly can be re-quoted.

Management re-quotes
assembly.

Wait for customer

response to new price.

72
 RMA Flowchart (January 2, 2002)
[Returned Materials Action]

Material fails the Material found to

incoming inspection. be defective.

Separate failed material.

Note the discrepancies and

inform the vendor.

Fill out RMA form

with correct
information.

Follow vendor’s
instructions and return
material to vendor.

Obtain an invoice
credit from vendor.

Obtain the proper materials

from the vendor.

Follow up with vendors as

required to obtain new materials
and address payments.

File RMA form and

return to Main
Flowchart using new
material.

73
 Sort Procedure Flowchart (January 2, 2002)

From a failed
Inspection on
Main Flowchart.

Inspect each assembly

in lot for dimension or
attribute in question.

Remove all non-conforming

(failing) assemblies and
place in a clearly marked
receptacle.

Determine the statistics or extent

of failure. Ask Management if a
waiver can be obtained (where
appropriate).

Yes.
Is waiver Document the waiver Follow the parameters
granted? in written form and of the waiver for using
insert into the WO. the material.

No.

Yes.
Can failed Determine the Rework
Thoroughly inspect
assemblies be procedures for assemblies
the reworked
reworked? reworking the according to
assemblies.
assemblies. procedure.

No.

Scrap the failed

assemblies and replace
them with new ones.

74
Return the passed
material to the
production flow for use.

Fill out the sort

form with the
statistics and
results of the sort.

Return to the
Main Flowchart
Inspection
procedures.

75