Process Map Example 2.xlsx

	A	B	D	E	F	G	H	I	J	K	L	M	N	O	P	Q	R	S	T	U	V	W	X	Y	Z	AA	AB	AC	AD	AE
1	Op. Numbers	Type	Process Description	Transform	Man-Minutes per unit	Machine Minutes per unit	Process Yield	Material Cost	Rolled Yield	Starts	Outs per Shift	Yielded Out per Shift	Capital Equipment Cost	Equip1	Equip2	Equip3	Work1	Work2	Work3	Work4	Work5	Work6	Exp1	Exp2	Exp3	Consume1	Consume2	Consume3	Consume4	Consume5
2	10	Kit	Obtain Materials for 5 assemblies	None	10	0	100%	$ -	75%	1.33	48	64	$ -				To and From Stockroom	Requisition form					Alumina Substrate	Adhesive	Laser Cut Polyfilm Mask	Surfactant	Di-H20	Class 100 gloves
3	20	Prep	Measure Components & Mix Solution	Component combined to create cleaning solution	10	0	100%	$ 5	75%	1.33	48	64		Substrate Holders (ceramic)			Measure Solutions	Arrange in work station	Move substrates to holder				1000 ml Beaker	Graduated Cylinder		Surfactant	Di-H20	Class 100 gloves
4	30	Clean	Clean Substrate	Surfacant cleaning to eliminate gross contamination	5	10	100%	$ -	75%	1.33	48	64	$ 10,000	Ultrasonic Cleaner (50°C, Set at 10)	Radiant Heater w/ airflow (80°C)	Substrate Holders (ceramic)	Transfer Solution to US Cleaner	Place holder in solution (5 mins)	Remove holder	Move to oven (5 mins)	Remove from oven	Substates cool to 20C				Cleanroon Wipes	Class 100 gloves
5	40	Clean	Plasma Clean Substrates	Plasma cleaning to eliminate molecular and oxides	2	10	100%	$ 5	75%	1.33	48	64	$ 15,000	Plasma Cleaner, 250W	Substrate Holders (ceramic)		Load Plasma : Substrates in holder	Close chamber and pump down	Set power (250W)	Set Time (10 mins). Start ccyle	Unload Plasma	Substates cool to 20C				Gas O2 99.99%	Class 100 gloves
6	50	Prep	Position substrate and polyfilm mask	Ensure placement and alignment before assembly	5	5	100%	$ 200	75%	1.33	96	127	$ 3,000	Film to Substrate align fixture	Vacuum Pump	Substrate Holders (ceramic)	Align substrate on fixture	Turn on Substrate vacuum	Align polyfilm	Turn on polyfilm vacuum	Close fixture and lock	Move to laminator press station				Class 100 gloves
7	60	Assembly	Film Lamination	Laminating to create premetalized substrate	2	10	98%	$ 50	75%	1.33	48	64	$ 20,000	Precision Laminator (120°C)	Substrate Holders (ceramic)		Set process temperature	Set process pressure (40 psi)	Load alignm tool still under vacuum	Activate press	Load alignm tool still under vacuum	Turn align tool vacuum off				Class 100 gloves
8	70	Polymer Desposition	Dispenser specialty adhesive	Low Frequency IR Absorber from substrate & adhesive	2	15	100%	$ 75	77%	1.30	32	42	$ 20,000	Robotic Adhesive Dispenser	Substrate Holders (ceramic)		Load syringe with adhesive	Run calibration and set-up	Load substrate holder	Run program	Unload substrate holder		Specialty Adhesive with Filler			2 mm sysringe	20 ml syringe	20 ml plunger
9	80	Cure	Cure specialty adhesive	Curing creates final absorber	2	120	98%	$ -	77%	1.30	4	5	$ 5,000	HEPA Radiant System (210°C)	Substrate Holders (ceramic)		Set oven and stabilize	Load substrate holder	Close oven	Run program	Unload substrate holder					Class 100 gloves
10	90	QA / Test	Thickness and Final Test	Assure final product meeting thickness and performance	5	5	80%	$ -	78%	1.28	96	122	$ 20,000	White Light Profilometer	Customer Spec'd Final Test		Thickness: Load substrate	Run LabView Program	Thickness: Unload substrate	Final Test: Load Substrate	Run Final Test	Final Test: Unload Substrate
11	100	Dicing	Thickness and Final Test	Assure final product meeting thickness and performance	5	5	98%	$ -	98%	1.02	96	98	$ 20,000	White Light Profilometer	Customer Spec'd Final Test		Thickness: Load substrate	Run LabView Program	Thickness: Unload substrate	Final Test: Load Substrate	Run Final Test	Final Test: Unload Substrate
12						Total Man Minutes	48	Sum of Man Minutes
13						Total Machine Minutes	180	Sum of Machine Minutes
14						Rolled Yield	75%	Product of Op10 * Op20…
15						Yielded Starts	1.33	1/Rolled Yield
16						Yielded Man Minutes	64	Total Man Minutes * Yielded Starts
17						Yielded Machine Minutes	239	Total Machine Minutes * Yielded Starts
18						Units per Substrate	50	Constant base on Substrate Size
19						Labor Cost per Hour	$45.00	Constant based on average labor rate
20						Labor Cost per Processed Substrate	$36.00	Labor Cost * Total Man Minutes
21						Standard Cost per Processed Substrate	$371.00	Sum of Material Cost
22						Standard Cost per Unit	$7.42	Standard Cost per Processed Substrate / Units per Substrate
23						Yielded Cost per Processed Substrate	$492.73	Standard Cost per Unit * Yielded Starts
24						Yielded Cost per Unit	$9.85	Yielded Cost per Processed Substrate / Unites per Substrate
25						Hour Per Shift	8	Constant based operations (not considering productivity, utilization, or efficiency)
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