Creating an operational or maintenance flow involves outlining the steps to ensure a process runs smoothly and efficiently. Let's design a maintenance flow for a common process: maintaining a commercial HVAC (Heating, Ventilation, and Air Conditioning) system. This flow will help ensure the system operates efficiently and reduces the likelihood of breakdowns.

HVAC System Maintenance Flow1.

Preparation

• Gather Tools and Materials:
  • Screwdrivers, wrenches, multimeter, cleaning supplies, replacement filters, belts, and lubricants.
• Review Maintenance Schedule:
  • Check the system's maintenance log to understand past issues and upcoming scheduled tasks.

2. Safety Precautions

• Power Down:
  • Turn off the HVAC system and disconnect power to ensure safety.
• Personal Protective Equipment (PPE):
  • Wear appropriate PPE such as gloves, goggles, and masks.

3. Inspection

• Visual Inspection:
  • Check for visible signs of wear, damage, or leaks in the system components.
• Component Check:
  • Inspect belts, pulleys, and electrical connections for wear and tear.
• Air Filter Inspection:
  • Check air filters for dirt and debris; replace if necessary.

4. Cleaning

• Coil Cleaning:
  • Clean evaporator and condenser coils to improve efficiency.
• Drain Lines:
  • Clear any blockages in the condensate drain lines to prevent water damage.
• Vent Cleaning:
  • Ensure all vents and ducts are free from obstructions.

5. Testing and Calibration

• Electrical Testing:
  • Use a multimeter to check electrical connections and ensure proper voltage and current.
• Thermostat Calibration:
  • Test and calibrate the thermostat for accurate temperature control.
• System Performance Test:
  • Run the system to check for unusual noises or vibrations.

6. Lubrication and Replacement

• Lubricate Moving Parts:
  • Apply lubricant to motors, bearings, and other moving parts as needed.
• Replace Worn Parts:
  • Replace any worn or damaged belts, filters, or other components.

7. Final Checks and Documentation

• Reassemble and Power On:
  • Reassemble any parts that were removed and restore power to the system.
• Operational Check:
  • Ensure the system is running smoothly and efficiently.
• Documentation:
  • Record all maintenance activities, findings, and replacements in the maintenance log.

8. Follow-Up

• Schedule Next Maintenance:
  • Set a date for the next routine maintenance check.
• Report Issues:
  • Report any significant issues to management or a specialized technician for further investigation.

This maintenance flow ensures that the HVAC system remains in good working condition, reducing the risk of unexpected failures and extending the system's lifespan. Regular maintenance also helps in maintaining energy efficiency, which can lead to cost savings.

Function Analysis task:

• Design an Operational flow or Maintenance flow for a process of your choice
• Each flow needs to have two (2) levels
• Each flow needs to have at least 15 steps (combined). Example, the operational flow first and second level should have a minimum of 15 steps total
• All process steps should be numbered
• Flow steps should be complete/logical
• Use standard flow diagram/charting symbols