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Process Flow Diagram Worksheet

A process flow diagram is the starting point for a PFMEA and control plan: it lists every step from receiving to shipping. This worksheet captures the same information as a table, adds cycle and wait times, and exports to Excel so you can feed the rest of your APQP package.

Download:

Op no.	Operation description	Step type	Machine / equipment	Input / material	Output / product characteristic	Special characteristic	Cycle time (s)	Wait / queue (min)	Cycle (min)
									2
									1.5833
									0.6667
									1
									2.5

Total cycle time (s)

465

Total wait (min)

395

Steps

Touch time (min)

7.75

Touch plus wait (min)

402.75

Rough lead time through the steps listed.

Touch time share of lead time

1.9%

Number steps to match the routing and PFMEA operation numbers. Mark special characteristics so they flow to the control plan. Cycle times are per piece in this sheet.

Compare floor flow with ERP routings

Optional: ask for a read-only comparison of your process steps and ERP routings.

Optional. The tool and every export work without this. No spam.

How to use the worksheet

List each step in the order the product moves, including inspections, transport, waiting and rework loops. Classify each step, name the machine, the input and the product characteristic created. Mark special characteristics so they carry into the PFMEA and control plan. Enter cycle time per piece in seconds and the typical wait before the step in minutes. The summary shows total touch time, rough lead time and the share of time the product is being worked.

Include rework and scrap paths, not only the ideal flow
Use the same operation numbers as your routing
Show outsourced steps such as heat treatment or plating
Record the characteristic produced at each step

Why the flow comes first

A PFMEA rates failure modes for each process step, so an incomplete flow means missing risks. Teams that start the PFMEA from memory usually forget transport damage, storage conditions or rework operations. Customers reviewing a PPAP package also expect the flow, PFMEA and control plan to match step for step. Build and walk the flow on the shop floor before the workshop, with an operator present.

Reading the result

The touch time share shows how much of the lead time is value-adding work and how much is waiting. Low percentages point to queue and batching problems rather than machine speed. Look at the steps with the longest waits, the special characteristics and any step with many incoming inputs, because these often hide the biggest risks. Use the numbers as a rough map, not a replacement for a proper time study.

Common mistakes and ERP links

Frequent errors are drawing the intended flow instead of the actual one, merging many operations into one box, and not revising the flow after a change. Compare the worksheet with the ERP routing: any step on the floor that is not in the routing is a data gap, and any routing step that nobody performs is clutter. Keep revision control so the PFMEA and control plan always reference the current flow.

Frequently Asked Questions

Is a process flow diagram required for PPAP?

Yes. A process flow diagram is one of the standard PPAP elements, and customers expect it to match the PFMEA and control plan. It can be a drawn diagram or a clear tabular flow like this worksheet.

Should I include inspection steps?

Yes. Inspections, tests, transport, storage and rework loops are part of the process and each can introduce or catch defects, so they belong in the flow and the PFMEA.

What symbols should I use?

There is no mandatory set. Many teams use operation, inspection, transport, delay and storage symbols. This worksheet records the same idea in the step type column.

Can I draw the diagram from this table?

Export to Excel or PDF and use the rows to build a visual flow in your diagram tool. The table keeps the data consistent while the picture is a presentation.

If you want to compare shop-floor flow against ERP routings automatically, Netray can discuss a read-only review. This worksheet works on its own.

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