How can Process Designers reduce costs through effective problem solving strategies?

Another reason why identifying the root cause is important is that it could allow us to figure out elements in our design that were not necessary in the first place. In these instances, once these bottlenecks are removed, it could improve the design and make the system work better. A win-win both in cost and efficiency.

Well, before identifying root cause, I would say to check on the FEED conditions based on which the existing design was built. No Process Design engineer would build a cost ineffective system. The existing system might have been built on specific assumptions and requirements. Before identifying root causes on why the present system is not working, first question WHY you think this is cost ineffective. What’s that change you’re adding to your balance sheets that you missed initially. Analyse the Management of Change (MOC) and then proceed to next steps.

1. Adequate understanding of the problem statement: 2. Proper consultations with applicable documentations and the team working with pre-existing designs 3. Re-defining the problem statement 4. Brainstorming and Teamwork 5. Solution evaluation, Implementation and Monitoring. The above highlighted are a guide framework to work with but each problem present its peculiar twist. So, respective process designers should pay close attention to the uniqueness of the problem they are trying to solve. For example, generating more revenue might be more prudent that just cutting cost in certain instances.

Según mi experiencia, es critico plantear el o los experimentos correctos para lograr reproducir el problema y de esta manera identificar la causa raíz.

I agree, when evaluating this question in relation to reducing costs we should reiterate the importance in utilizing the methods mentioned above. This will eliminate the possibility of implementing solutions that do not the address the root cause which will can quickly become costly.

One thing I've found helpful in define the problem statement is the defined objective function. This objective could be related to in rease productivity, increase profit or be related to environmental issues. But one thing which is important in solving the problem is that the objective function must be multidisciplinary and cover multiple criteria. Solving the problem According to a objective can causes one or multiple issues in future.

The problem statement needs to balance both the user problem and business problem. Example: Users want a way show expertise and mastery to their peers so they can get better jobs or salary. LinkedIn wants a way to engage and accelerate active user engagement so they can remain relevant and continue to receive funding. Both the business and the user needs collide and are self serving.

Define the problem statement: Once you have identified the root cause of a problem, the next step is to clearly articulate the issue, detailing its impact and the specific aspects that need resolution.

All too often, value engineering by exploring economic alternative works. This will mean that after initial concert in design is established, a broader view of the design can then be carefully reviewed, looking at individual unit within the system that can be improved economically. A good understanding of the design scope is paramount. Lesson learned and practical solution from similar project are good goby to reducing design cost.

Into Mainstream, Engineering projects tend to be made cost effective that serves the purpose optimistically while adopting alternatives that are Environmentally accepted as per EPA. The basic analogy is: Analyze Plan Implement Evaluate There are certain stages where the alternative can be implemented effectively. 1.At FEED stage 2.During Conceptual Studies 3.Adopting Process Technology 4.Reviewing Data sheets for Equipment 5.Tendering out for Equipment purchase. 6.Effective Simulation tools for optimization Note: Generate as many possibilities to make process design feasible in terms of Cost while maintaining the quality of Process & durability in the long run.

totally agree, only the addition is to develop different measure methodologies to verify that the solution is correct and not only counting on one method

Agree, definitely will get results.

Many times we forget to follow up after implementation. KPIs are a good start, but regular Gemba walks will provide a better perspective on the impact of the solution and also identify other opportunities that may arise.

Process designers can reduce costs through effective problem-solving strategies by employing techniques such as root cause analysis and value stream mapping. By identifying the underlying causes of inefficiencies or bottlenecks in the process and mapping out the flow of value, designers can implement targeted solutions that eliminate waste and streamline operations, ultimately reducing costs. Additionally, employing lean principles and continuous improvement methodologies, such as Kaizen, can further optimize the process and drive cost savings.

I found this to be great work. Instead of a blame game, working on the root cause should be the main purpose. The ultimate goal is to deliver quality in work, such that the clients are happy to invest for future projects.

Learning and improvement: Problem solving is not a one-time event but rather an ongoing process. Continuous learning from experiences, feedback, and results is essential for refining strategies and enhancing problem-solving skills over time.

one thing I found helpful is using continuous improvement methodologies (lean , six sigma), also lesson learned while solving problems one of the best solutions to help and guide

DMAIC and DMADV are solving strategies that aim to reduce costs by addressing problems and optimizing processes. DMAIC (Define-Measure-Analyze-Improve-Control) is an incremental problem-solving strategy that focuses on improving existing processes. It involves defining project goals, measuring key aspects and collecting data, analyzing data to identify root causes, making improvements and controlling the improved process. DMADV (Define-Measure-Analyze-Design-Verify) is a strategy for designing new processes. It includes defining process goals, measuring critical-to-quality characteristics, analyzing data to determine the best design, designing and testing the product or process, and verifying & validate that the design meets requirements.

Process designers must adopt design for six sigma methodology and should look to leverage Toyota House of quality as well as product FMEA tools to address current as well as potential problems users/business may experience.

Utilize automation and technology to streamline processes, boost accuracy, and lower labor expenses. Encourage cross-functional collaboration to leverage diverse expertise and perspectives, fostering innovation and cost-effective solutions.