What are the best methods for evaluating and adopting new manufacturing processes?

Introducing new technological processes is only half of the equation. A company's people also need to be aligned and competent within the new environment. In my experience, an often overlooked aspect in the assessment stage is assessing people's competence and (more importantly) commitment to change. This is often delayed until after new processes / technologies are implemented, but should be done concurrently with (or prior to) the 'assessment of the current state'.

Yes, a new process will typically require the ATeam from the plant (best mechanical, electrical, process engineering, and operators) to successfully start up a complex process in a timely fashion. Long hours, good teamwork, and supportive management are also key elements.

I think it's necessary to understand the current situation before considering the new mfg process. If an organization is based on Value Strem Mapping, they can understand current material flow and Information flow. based on that, consider the future requirements and draw the future dream VSM. If an Organization based on SWOT, want to plan a new manufacturing system to convert weak points into Strengths. and also they can think about how to take advantage of opportunities and how to reduce the current threats. based on that they can define the new manufacturing system. Another thing is when defining the manufacturing process needs to focus on the customers, current Operational performance and expectations.

Evaluating and adopting new manufacturing processes is a critical task that requires a systematic approach to ensure successful implementation. 1. Identify and clearly define the specific needs and goals of your manufacturing process. 2.Understand the problems or limitations with the current processes. 3.Conduct a thorough cost-benefit analysis. 4.Conduct a comprehensive feasibility study to assess the technical, economic, and operational viability of the new manufacturing process. 5.Implement a small-scale pilot of the new manufacturing process to test its functionality and performance. 7.Ensure that the new manufacturing process complies the regulatory requirement.

Early new project stability KPI 1. Production process stability is meaning of standardized process implementation. 2. standardized operation is dependent on Process documents and instructions. 3.Procees control by system digitalization, monitoring, measure,analysis, improve. 4.KPI plan vs actual,OEE,FTT,and scrap real time Achivement. 5.FMEA,control chart,process flow,PDCA

When thinking about the new manufacturing process, there should be three things to consider. Such as Organization Vision, Customer Expectation and Best Practices in the world. The organization's vision, Mission, and Key objectives need to be achieved through the manufacturing process going to be set up. It should be aligned with the customer's requirements. and also it should be updated process and match with the current trends and world-famous results generated systems.

Commonly, the auto industry requires suppliers to provide a PPAP report, ensuring the manufacturing process complies with all specifications. Implementing PPAPs for your processes in any industry can support your SPC, offering both qualitative and quantitative data to confirm your capability to deliver high-quality products to your customers. While it may involve an initial investment, from a quality assurance perspective, it's unquestionably worthwhile.

After completing the manufacturing process preparation, before implementation throughout the organization, it should be validated. even proven concepts in the world organizations have to be customised based on the organization's status. Usually developed new processes need to be applied in the model area and after proper evaluation only it has to spread throughout the factory. It has to be monitored closely and frequently needs to take feedback from all relevant stakeholders. based on that whatever adjustments need to be made and it is also on trial and error basis. After all, verification is completed and if the design process shows the required results, then only the process can be implemented throughout the organization

During the implementation, it is required to prepare a comprehensive plan and it should include both parts, strategic and tactical. based on each and every part of the new process implementations, sometimes it is required to prepare a few separate tactical plans. it is important to understand the constraints and risks behind the projects to consider the constraints and prepare a risk mitigation plan. If unwillingness to change is one constraint, it has to be addressed through proper awareness and training. That means the organization want to prepare a change management plan and it can include some rewarding and motivational sub-plans also. Budgets and resource allocations, Scop, timelines, implementation teams, etc. need to be focused also.

Monitoring and improvement are a must during the implementation process as well as after implementing the manufacturing processes. Therefore, it is required to set up a measuring system and needs to set up proper frequent review mechanism. based on that can identify the variations and the organization wants to conduct the required adjustment on the prepared manufacturing process.

Need for adoption of new mfg process must be evaluated primarily from business need point of view. Unless that is firmly realised, one should not go for new process, as that necessiates changes across the value chain which is complex. The changes may be in - addition of new machine & scraping of old machine. -changes in process flow and hence layout. -training of people for operation of new machine and new process. - supplier preparation to supply material as per new process. -run down of existing material to avoid scraping of existing material. Testing and validation is another step before adopting the new process; We may have to scrap the trial materials in this stage. So do not go for new process, unless there is a compelling biz need.