How to create an APQP process flow diagram

A process flow diagram is a visual sequence of the activities used to make, handle, inspect, store, and ship a product. It gives the APQP team a shared, step-by-step view of the process.

What to include

Process steps

Show each meaningful operation in order: receiving, material preparation, manufacturing, assembly, inspection or test, rework where allowed, packaging, storage, and shipping as applicable.

Inputs and outputs

Identify material, components, information, or equipment entering a step and the product or record leaving it. Include external suppliers and outsourced operations where they affect the process.

Decision and rework paths

Show inspection decisions, nonconforming-material paths, rework loops, and segregation routes. Do not hide these paths because they are inconvenient; they create risks that require analysis and control.

Build it on the shop floor

  1. Begin with the approved process concept, then walk the route with operators, supervisors, maintenance, quality, and material-handling personnel.
  2. Use clear step names and unique step numbers. Keep those identifiers unchanged in the PFMEA and control plan.
  3. Confirm that every actual operation and transfer is represented, including temporary storage and outsourced work.
  4. Review the completed flow with the team before risk analysis.
Common failure: treating the flow as a drawing for a customer file. If the process changes, update the flow first or at the same time as the PFMEA and control plan; then evaluate the change using your document-control process.

Use the completed flow to structure the Process FMEA, then define the operational controls in the Control Plan.