Struggling to optimize processes in your plant facility?

For any required change we must have basis of our design intent and Process audits is the best tool for it. In my view if we want to achieve optimization in process plant operations, we must thoroughly audit the process which will give us the area of concern and focus on on the troubled one which hinders the optimization process.

Steve. You are correct, correct and correct. Keep it simple but process flow (VSM) will show the areas to attack and where the BIG fish ($$$) are hiding. I always started with a process map.

A auditoria de processos é um passo crucial para otimizar a planta e alcan?ar uma opera??o mais eficiente e econ?mica. Ao identificar e eliminar ineficiências, as empresas podem reduzir custos, aumentar a produtividade e estabelecer bases sólidas para um crescimento sustentável. Investir tempo e recursos em uma auditoria de processos abrangente é, portanto, um investimento estratégico que pode gerar benefícios significativos a longo prazo.

I will suggest calling this first step Genba Walk. While walking the floor you will be able to identify the waste in the process and sure, you have to be able to put into paper all your findings.

Besides identifying and eliminating waste, the objective of Lean Manufacturing is to connect Process and create flow. Clearing the process of waste, then the connection and flow starts to happen

A análise de fluxo de trabalho é uma ferramenta poderosa para melhorar a eficiência operacional de uma organiza??o. Ao identificar e eliminar ineficiências, as empresas podem reduzir atrasos, aumentar a produtividade e melhorar a qualidade dos produtos ou servi?os oferecidos. Além disso, ao adotar um processo contínuo de revis?o e adapta??o, as organiza??es se mantêm ágeis e preparadas para enfrentar novas demandas e inova??es tecnológicas. Investir na análise de fluxo de trabalho é, portanto, um passo estratégico para alcan?ar uma opera??o mais eficiente e competitiva.

Returning to foundational principles is crucial, particularly in the context of Lean methodologies and the Visual Factory concept. It is essential to conduct a thorough analysis of the current tools in use, and explore opportunities for innovation through the adoption of emerging technologies. These advancements can foster a stronger sense of belonging among team members. Often, the longevity of implemented tools and strategies is contingent upon effective communication and active involvement of personnel. Without these elements, even the most promising initiatives may not sustain over time. Therefore, it is imperative to ensure that the intended message is conveyed accurately and that individuals are actively engaged in the process.

To start from the principles are important in optimizing any process. It should start from "Sort" (5S) the activities, which one is VA/NVA/NVAN. Then we go to other tools. Identifying these "sorting" activities is somehow overlooked because everything looks important to keep. Meanwhile, if we don't know which one brings the 'real' value add, any project of "optimizing" would be difficult to deploy.

Os princípios de manufatura enxuta s?o fundamentais para a otimiza??o dos processos produtivos. Ao focar na elimina??o dos sete desperdícios, as organiza??es podem melhorar o fluxo e a qualidade de suas opera??es, ao mesmo tempo que reduzem custos. Mais do que um conjunto de ferramentas, Lean é uma mentalidade que capacita a equipe a buscar continuamente ineficiências e resolver problemas. Implementar essa filosofia de forma abrangente e contínua pode transformar a opera??o de uma empresa, levando-a a níveis superiores de eficiência e competitividade.

In my view for Process plant optimization plant hardware must be aligned with the current changed scenario of digitization. AI and ML is the essential now for effective process plant monitoring and thus by optimization can be done. Process civilization with Artifical intelligence will help to give better diagnosis and numerous alternatives to select best optimum one.

Investir em tecnologia é essencial para manter a competitividade e eficiência nas opera??es industriais modernas. A automa??o, softwares avan?ados de gerenciamento e a integra??o de IoT e Big Data oferecem melhorias substanciais na produtividade, qualidade e capacidade de resposta ao mercado. Embora os custos iniciais possam ser altos, os benefícios de longo prazo – em termos de redu??o de custos, aumento da flexibilidade e melhoria na tomada de decis?es – justificam amplamente o investimento. A atualiza??o tecnológica n?o é apenas uma op??o, mas uma necessidade estratégica para qualquer planta que busca operar no mais alto nível de eficiência e competitividade.

Technology can sometimes help leap frog a previously missed incremental improvement opportunity and unlock potential previously unrealized. The best tech that currently is favoured is IOT devices that help provide measurement, feedback and control.

In my view, one of the most key and most overlooked aspects of continuous improvement are people and relationship management. The ability to align objectives across departments and throughout an organization is likely a key aspect of CI which doesn’t have a roadmap but the most travelled on the journey of continuous improvement.

Continual improvement is the perpetual way to sustain with optimized plant operation which we achieved with the help of AI and digitization. Implementing continuous improvements best practices and putting system in place to get continuous improvement in process plant operations.