"Order Quote Flowchart"
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