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Here's how you can assess the feasibility of new processes in manufacturing operations.

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When considering the introduction of new processes in manufacturing operations, it's crucial to evaluate their feasibility to ensure they align with your production goals and capabilities. This assessment is a multi-faceted process that involves analyzing technical, economic, and operational factors. By taking a systematic approach, you can make informed decisions that enhance efficiency, reduce costs, and maintain quality. The following sections will guide you through key considerations to help you determine whether a new manufacturing process is right for your operation.

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Tushar Chaudhari

Digital Transformation | IIM Mumbai | MNNIT Allahabad | PGP - AIML | CPIM - APICS | SCM | Operations | Process…

1 Define Goals

Begin by clearly defining what you aim to achieve with the new process. Are you looking to improve product quality, increase production speed, reduce costs, or perhaps implement more sustainable practices? Having well-articulated goals allows you to measure the new process against specific criteria and determine if it can deliver the desired outcomes. This clarity is essential for aligning the new process with your overall business strategy and for setting benchmarks to evaluate its success.

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Tushar Chaudhari

Digital Transformation | IIM Mumbai | MNNIT Allahabad | PGP - AIML | CPIM - APICS | SCM | Operations | Process Excellence | Technology Enablement | Projects Management | Analytics | Tableau | Python
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I think, the first thing to start with is to ask why the change is required from the first case, if some process is already in process. That actually starts with defining some problem statement what is the problem that we are trying to solve by implementing a new process and then defining the Goals. A Wrong problem definition can kill the entire objective and derail the entire feasibility check.

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Lalitha Bayaravan

LinkedIn Top Manufacturing Voice | Lean Leader | Lean Six Sigma & CI | Driving Operational Excellence & Process Optimization
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Clearly define the objectives the new process aims to achieve (e.g., cost reduction, quality improvement, capacity enhancement). Identify specific requirements such as production volumes, quality standards, regulatory compliance, and resource utilization.

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2 Analyze Costs

Cost analysis is fundamental in assessing new manufacturing processes. You need to consider not only the initial investment in equipment and technology but also the long-term operational costs. This includes maintenance, energy consumption, labor, and potential disruptions during integration. A thorough cost analysis will help you understand the financial impact of the new process and whether the expected benefits justify the expenses.

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Tushar Chaudhari

Digital Transformation | IIM Mumbai | MNNIT Allahabad | PGP - AIML | CPIM - APICS | SCM | Operations | Process Excellence | Technology Enablement | Projects Management | Analytics | Tableau | Python
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Main purpose to analyze here is to calculate ROI / IRR for the money to be invested and how much the investment will result in higher sales / better margins or reduce costs to overcome the investments with a pre-determined period of time.

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3 Technical Review

Conduct a technical review of the new process to ensure it is compatible with your existing manufacturing infrastructure. This involves evaluating the technical specifications, material requirements, and whether your current workforce has the necessary skills or if training is needed. It's also important to consider if the new process can be seamlessly integrated into your production line or if significant modifications are required.

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Tushar Chaudhari

Digital Transformation | IIM Mumbai | MNNIT Allahabad | PGP - AIML | CPIM - APICS | SCM | Operations | Process Excellence | Technology Enablement | Projects Management | Analytics | Tableau | Python
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Once economy of process change allows to go ahead, this is the place where actual technical change feasibility will be analyzed for the proposed change and consequences of the changes to be evaluated.

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4 Risk Assessment

Evaluating risks associated with implementing a new manufacturing process is crucial. Consider both the likelihood and impact of potential issues such as supply chain disruptions, equipment failure, or quality control problems. A comprehensive risk assessment will help you identify mitigation strategies and decide if the potential rewards of the new process outweigh the risks.

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5 Market Analysis

Understanding market demand is key when introducing a new process. Analyze current and future market trends to ensure that the products produced by the new process will meet customer needs and preferences. Consider if there is a sufficient market size to justify the investment and if the process allows for flexibility to adapt to changing market conditions.

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6 Pilot Testing

Before fully committing to a new process, conduct pilot testing to gather real-world data on its performance. A pilot run can reveal unforeseen challenges and provide insights into how the process interacts with other elements of production. This step is vital for validating assumptions made during the feasibility assessment and can lead to necessary adjustments before scaling up.

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7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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Tushar Chaudhari

Digital Transformation | IIM Mumbai | MNNIT Allahabad | PGP - AIML | CPIM - APICS | SCM | Operations | Process Excellence | Technology Enablement | Projects Management | Analytics | Tableau | Python
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Scalability and self monitoring and correction of the process is another factor that should be considered when we want to run the process on a much larger scale. Self Monitoring is the aspect where process may be set on its auto mode with minimum manual interventions.

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Here's how you can assess the feasibility of new processes in manufacturing operations.

1

2

3

4

5

6

7

1 Define Goals

2 Analyze Costs

3 Technical Review

4 Risk Assessment

5 Market Analysis

6 Pilot Testing

7 Here’s what else to consider

Manufacturing Operations

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Here's how you can assess the feasibility of new processes in manufacturing operations.

1

2

3

4

5

6

7

1 Define Goals

2 Analyze Costs

3 Technical Review

4 Risk Assessment

5 Market Analysis

6 Pilot Testing

7 Here’s what else to consider

Manufacturing Operations

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