Free template
Process flow diagram template
A process flow diagram is a drawing of every step a product goes through, in order, from the material coming in to the product going out: the operations, the moves, the checks, the waits and the storage, with the decisions and rework loops between them. It is the start of most process work: a PFMEA and a control plan follow its steps, and a value stream map adds times and inventory to the same flow. Page 1 of this template has a key of flowchart symbols (start or end, process step, decision, input or output, document, connector and flow direction) and a large squared area to draw the flow. Page 2 is a step table: for each step, what happens, the process chart symbol (operation, transport, inspection, delay or storage), the machine or station, time, distance, the characteristic checked and the control, with totals of each kind of step.
Free to use: print it, copy it and edit it for your team. Enter your name and work email once to download.
When to use it
When to use a process flow diagram
- Before a PFMEA or control plan, so both follow the same steps in the same order.
- When setting up a new process or a new line, or moving one.
- To train people on a process they only see part of.
- As the first look at waste: every move, wait and storage step is a question to ask.
How to fill it in
- 1
Set the start and end
Where the flow begins (material received, order released) and ends (packed, shipped). Agree the boundaries before you draw.
- 2
Walk the process
Follow a part through the process and draw each step as it happens, including checks, moves, waits, storage and rework loops. Draw what happens, not what the procedure says.
- 3
Use the symbols
One symbol per step: rectangles for process steps, diamonds for decisions with a yes and a no path, arrows for the flow. Number the steps.
- 4
Fill in the step table
For each numbered step, circle its process chart symbol and write the machine, time, distance and any characteristic checked with its control.
- 5
Count and question
Total the operations, transports, inspections, delays and storages. Only operations change the product; ask why each of the others is there.
- 6
Keep it current
Give the diagram a revision and update it when the process changes, together with the PFMEA and control plan that follow it.
A filled-in example
Illustrative, not a benchmarkAn example: a machined shaft from bar stock to packing (illustrative).
- 14 steps from receiving to packing: 5 operations, 4 transports, 2 inspections, 2 delays and 1 storage.
- Operations: saw, turn, mill a keyway, heat treat (outside process), grind.
- Transports: 4 moves totalling 180 m, two of them to and from the heat treat area.
- Delays: waiting for the outside heat treat batch and waiting for the first-off check at the grinder.
The team used the diagram as the base for the PFMEA and control plan, and the 180 m of moves and the first-off wait became the first two improvement ideas.
Common mistakes
Drawing the procedure
The written process leaves out the waits, the rework loops and the extra moves. Walk it and draw what you see.
Leaving out decisions
Every check that can fail needs a no path: rework, scrap, hold. A flow with only yes paths hides where parts go when things go wrong.
Steps too big or too small
"Machine the part" is too coarse for a PFMEA; every hand movement is too fine. One step per change of machine, check, move or wait is a good level.
Out of step with the PFMEA
If the steps are numbered differently in the diagram, the PFMEA and the control plan, things fall through the gaps. Use one numbering.
Download the template
Free to use: print it, copy it and edit it for your team. Enter your name and work email once to download.
Run this template in LeanSuite
LeanSuite builds a current-state value stream map from video of each process step, with measured cycle times, inventory between steps and lead time, and exports it to PNG, PDF or VSDX for Visio.
In the lean glossary
FAQ
Process flow diagram template: common questions
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A shift handover sheet, a red tag log, a changeover checklist for one machine: if your team uses it on the floor, ask.