Attachment 0004 - Low Level Process Map - updated.pdf

Low Level Process Map

Basics Recommended Format

Generic Example

9 September 2021

Basics

• Low Level Process Map An evolution of a production flowchart, identifying

• Inputs – What’s needed at this step

• Outputs – What’s the product/result of this step

• Key Activities – What actions yield the step’s output

Processing of inputs and previous steps’ outputs

• Safety Critical Characteristic (SCC) Notation All SCC-related information employs red color font or shapes Non-SCC information employs black color font

Recommended Format:

Critical Characteristics Process Map

Contractor format is acceptable, provided the alternate format is explained

(as in the following slides)

Critical Characteristics Process Map Format

Level “n” Process Map

Start Description Description Description

1.2 1.3 1.4

EndDescription

•Input •Input

•Output •Output •Output •Output

•Key Activities •Key Activities

1.1

Key:

Input: -----

Output: -----

Process: -----

Critical Defect -----

“1.1” means this is a 2nd Level Map of Level 1’s Step 1

Red box means there is an SCC created or detected at a lower level Map

Red Letters in Input, Output or Key Activities mean the SCC is created or detected at this very point in the Map

Black lines denote Process Flow

•Key Activities •Key Activities

•Key Activities •Key Activities

•Key Activities [SCC] •Key Activities •Gov’t Notifications [Agency-Report]

See next slide for Steps’ nomenclature

Government notifications include the Agency(ies) and reports/documents used to communicate SCC

Step Nomenclature

Description

Inputs

Outputs

1.2.1

Numbering Level Step

1 1 1

1.2 2 2

1.2.1 3 1

Previous Next

•Key Activities •Safety Critical Activity [identify SCC]

Identify SCC-related activity (creation or detection) in red font

Spell out SCC within [brackets] Place blue/green boxes as to best fit within map

Example

Representation of a Production Line for illustration and reference purposes

Safety Critical Characteristics (SCCs) Identified in this Map

Code Description A Material Structure Unsound

B Interface Thread Incorrect

C Leak Rate Over Max

D Presence of Interface Holes

E Incorrect Assembly

• Identify what SCCs are portrayed within the map Defects herein are used solely for illustration

• State “No SCCs in map” for submittals without SCCs

Topmost Level

• Steps 1 & 4 identify the creation and detection points for the Safety Criticals (red text).

A lower level map may not be necessary

• Steps 2 & 3 identify Safety Criticals are either created or detected or both in a sub-processes.

A lower level map is necessary

Receive Materials & Parts

Manufacture Components

Assemble Components

Package AssembliesStart

End

Suppliers’ parts Raw Material

Parts Received Material Received Segregated non-conforming material

Raw Material Standing Procedures Trained Personnel

Receiving Inspection Inventory Operations

Manufacturing Operations

Accepted parts Segregated non-conforming material

Suppliers’ Parts Standing Procedures Trained Personnel

Specialized Equipment

Manufacturing Operations

Accepted assemblies Segregated non-conforming material

Packaging Operation Shipping Inspection

Standing Procedures Trained Personnel

Specialized Pkg. Materials

Assemblies Ready to Ship

Segregated non-conforming material

3 4

Step 2 Detailed [1/2]

• Sub-Steps identify creation and detection of SCCs, as well as proactive measures to prevent them (e.g., in-process check)

Sometimes the process inputs can be enable creation of SCCs

• Ovals are off-page connectors Disposition off-page connector refers to SCC non-conformance process handling

Metal Treatment

Material Inspection1

2.4

Accepted parts

Rough shape parts

Inspection Process Test Standards

Standing Procedures Qualified Personnel

Heat Controls for [Material Structure Unsound]

Forge Controls for [Material Structure Unsound]

In-Process Mechanical Properties Test

Non-Destructive Inspection for [Material

Structure Unsound]

Structurally checked parts

2.1 2.2

Accept

SCC?

Disposition

No

Manufacture Components

Standing Procedures Equipment Set-ups

Special Machining Operation for [Interface

Threads Incorrect] In-Process Check for [Leak Rate Over Max] Machining Operations

2.3

Accept

SCC?

Disposition

No

Final shape parts

Yes Yes

Step 2 Detailed [2/2]

• Note not every input or activity is SCC-defect related

• Step numbering reflects lower level

All 2.x are part of Topmost Level step 2

Assemble Parts

Final Inspection2.3 3

Accepted Suppliers’ parts

Standing Process

Complete parts

Calibration Standing Procedures Qualified Personnel

Gages

Heat Controls Finish Controls

Mechanical Properties Test

Automated Gage for [Leak Rate Over Max] Automated Visual for

[Presence of Interface Holes] Manual Inspections Visual Inspections Inspected parts

2.4 2.5

Accept

SCC?

Disposition

No

Yes

Step 3 Detailed

• Note inspection can happen at latter stages of production

Final Metal

Treatment

Final Inspection2.3 3

No additional input

Complete parts

Calibration Standing Procedures Qualified Personnel

Gages

Heat Controls Finish Controls

In-Process Mechanical Properties Test

Automated Gage for [Interface Thread Incorrect]

Automated Visual for [Incorrect Assembly] Manual Inspections Visual Inspections Inspected parts

2.4 2.5

Accept

SCC?

Disposition

No

Yes

Included for illustration Not required

SCC Disposition

• Include sub-map addressing how SCC dispositions are handled

Based upon Critical Characteristic Control Plans (CCCP) and/or Critical Plans of Action (CPOA)

• Only applies to SCCs

Assess Causes

Notify Government

Continue Production

Contract Requirements Quantity

Defect(s) in question Operations involved

Malfunction facts Corrective Actions

Shutdown (if required)

Root Cause Analysis or 6 Sigma Methods or other failure resolution tools

Present facts Present Actions

Request Go-Forward approval

Gov’t addresses Go-Forward

4.1 4.2

Approval by

Gov’t?

No

Yes

Disposition

Contract Requirements

Re-Start Authorized

Production resumed

Complete Corrective Actions (as applicable)

Re-Start production

4.3