Process Flowchart Exercise$-$Coffee Machine

$($Part of a Case Study$)$

Canadian and American suppliers send components for the coffee machines $($bodies$,$ bases, electrical,$)$ to a Distribution Centre $($DC$)$ in Oakville, which is $5km$ away from the factory. A sample of $4$ components per box is inspected, before the components are being stored. Rejected boxes are returned to suppliers. Kits of all components for one day's production are sent directly to the different workstations of the assembly line, every night for the next day's production.

A tour of the assembly operation indicated that there is an assembly line, with $7$ employees, who assemble a standard coffee machine.

The assembly starts at the first workstation of the line, with the assembly of the main body. Then, fitting of the base to the main body is carried out, followed with the adding of the heating element. The next operations in sequence are: adding of electrical wiring, connecting transformer, connecting switches, sticking labels. It ends with final electrical and visual inspection. Each coffee machine is then packed into its carton box, and every $20$ cartons are packed again onto one pallet.

Coffee machines that are found faulty at the final inspection are sent to a special operator, away from the assembly line, for repair. After being repaired they are returned to the final inspection, at the end of the assembly line.

As per instructions from Sales, complete pallets are sent either to the DC in Oakville, for storage, or delivered directly to customers, from the adjacent dispatch area.

Assignment:

Draw a detailed and sequential Process Flow Chart for the manufacturing and other logistics and quality activities, using the standard symbols that we discussed in class.