Struggling to innovate in process design?

Change is the only constant in any industry. Changes should always happen for betterment and processes/practices get evolved with time. Embracing change can benefit in all the aspects of an ecosystem. Sticking to the existing practices comes naturally (newton's first law) but in this continuously evolving world, one has to question every design which is operating at same efficiency for long without any improvement. Believing that "scope of improvement is always there" is the key for embracing change. There are multiple examples where very successful businesses having monopoly, just vanished because they did not accept changing with time.

The focus has to be on problem in hand. Before proceeding to solve for that problem one needs to calibrate: 1. Is the problem identified the real problem (5Y, Design thinking, Assessment) 2. Does the problem worth solving for (80/20) 3. How big is the problem against best in class (Benchmark with BIC) Accordingly go behind looking to solve with most optimized way, again not just throwing a piece of tech but to be looked at from all levers: 1. Potential to standardize / streamline with acceptable change mgmt 2. Ability to sweat current tools/frameworks/platforms 3. Residual if significant with tech / point sol

Point to ponder before thinking of change and then embracing the same: 1. Benchmark current processes and the outcomes with comparable industry 2. Ensure that HES, $ and key process output effectiveness and efficiency metrics are benchmarked 3. Understand the gaps and start thinking about fundamental changes that could impact the gaps identified 4. Share the output gaps information with employees and workers + seek their thoughts and inputs 5. Develop list of process input impacting variables (including both continuous and discrete variables) and investigate-evaluate best technology to redesign 5. Use all the above as a basis to drive ‘change management’ activities - which in itself can be highly involved in terms of steps to follow

To overcome struggles in innovating process design, foster a growth mindset and encourage cross-functional collaboration to bring diverse perspectives. Simplify complex problems by breaking them into manageable parts and embrace a test-and-learn approach with small-scale experiments. Leverage technology to identify inefficiencies, seek external inspiration for fresh ideas, and invest in training to equip teams with the right skills. Finally, celebrate small wins to maintain momentum and encourage continued innovation.

In designing a process, accepting change is vital for innovative outcomes. Yet, it is common for teams to get mired in "the way we have always done it." To liberate ourselves, we can encourage a shift in the collective team mindset. One method I've found useful is to regularly interrogate existing processes. We can ask, "Why do we do it this way?" and "Could we do it better?" It is also necessary to create an environment where new ideas, no matter how crazy, are welcomed. A good culture will reward risk-taking and learn from failures. Remember, when challenging the status quo, we often stumble upon fresh, creative solutions.

In my experience, seeking inspiration from diverse sources is key to innovative process design. Look beyond your industry - I've found great ideas in unexpected places. Attend conferences, read widely, and network with professionals from different fields. Sometimes, a manufacturing technique can inspire a software development process, or vice versa. Encourage your team to share interesting concepts they come across. I've seen cross-pollination of ideas lead to breakthrough innovations. Don't be afraid to adapt concepts from other domains to fit your needs. Fresh perspectives often spark creativity and help overcome stubborn process challenges.

Esto es lo que muchas veces llamamos: ejemplos de mejores prácticas. Muchas veces mirar otras industrias y como abarcaron la innovación de procesos, ayuda a tener una fuente de inspiración para tu propia realidad.

Die Suche nach Inspiration sollte systematisch erfolgen. Analysen von Best-Practice-Beispielen und Innovationsscouting sind wertvolle Methoden, um neue Ideen zu entdecken. Der Cross-Industry Innovation Ansatz, bei dem Unternehmen Techniken aus anderen Branchen adaptieren, kann zu innovativen L?sungen führen. Beispielsweise kann die Lean-Philosophie aus der Fertigung auf andere Bereiche übertragen werden, um Prozesse zu optimieren. Der Besuch von Fachkonferenzen, das Studium von Case Studies und der Austausch mit Branchenspezialisten sind effektive Wege, um frische Perspektiven zu gewinnen.

looking beyond our immediate environment can be a very great help to the design of a process. Exposure to different industries can bring in the new things and methods that might not be found within the experts of our field. Conferences and case studies have been proven to be excellent ways to get familiar with innovative practices and cutting-edge technologies. Apart from those visits to the firms that are famous for their effective processes, one can also get some practical knowledge of successful strategies from case studies. The willingness to be open and the continuous effort to get inspiration from different sources are truly the factors that result in the improvement of processes as well as the generation of creative ideas.

No solo mirar el entorno industrial es suficiente, benchmarck con industrias exitosas es suficiente, apoyarte del outsoucing tamien aporta, incluso la experiencia misma a travez del tiempo y el haber trabajado en diferentes empresas suma considerablemente sirben como inspiración, a eso le llamo crecimiento profesional y aportación a la industia.

Collaboration in this new age, can become way of utilizing available resources across the globe to fastrack innovation as well as its practical implementation. Available talent and knowledge at different geographic locations communicating with each other can add to build one bigger and better human intelligence bank where every idea is being captured and evaluated and none of them is being wasted.

Root out the causes and make a deep understanding of obstacles then engage all the stakeholders and analyse their perspectives and suggestions. Arrange the collaboration with all the respective departments involved and come up with a single strong idea towards the design success.

It is vital to encourage collaboration among as many different people as possible to foster truly innovative process design. At a minimum, this means working across departmental boundaries; it's surprising how often people who ought to be working together don't even know what the other group is doing. The best results I've seen have come from involving teams that also include end users or customers. Process design in those cases is really a co-design effort. And of course, it helps to have everyone involved in the process working toward the same goal. That means also being collaborative at the top and between levels of authority.

Für eine effektive Zusammenarbeit ist der Einsatz von Cross-Functional Teams entscheidend. Solche Teams bringen diverse Perspektiven zusammen und f?rdern eine Interdisziplin?re Zusammenarbeit. Methoden wie Design Thinking und Brainstorming-Sessions k?nnen die Kreativit?t und Probleml?sungsf?higkeiten der Teammitglieder steigern. Das Konzept der Co-Creation involviert Stakeholder und Endbenutzer in den Entwicklungsprozess und kann zu praxisnahen und benutzerfreundlichen L?sungen führen. Kommunikationstools und Kollaborationsplattformen unterstützen eine transparente und effektive Zusammenarbeit.

Equipo multidisciplinario, el apoyo de personas expertas en su área tales como Calidad, Logística, Mantenimiento, y principalmente el área productiva aportan en diferentes formas que aseguran la optimización de cualquier proceso ya sea productivo, flujo de información he incluso de relación personal. Comparte tu experiencia y conocimiento al maximo.

Leveraging the technology can really help to improve the Process streamlining, but we must be cautious of choosing the right technologies otherwise it may lead to the total disaster, especially in production. We must try to choose futuristic technologies and software to be ahead and competitive in the industry domain.

Leveraging technology is the need of the hour. "Data is the new oil" will have to be taken into consideration while thinking about process improvements/intensifications. Particularly in chemicals manufacturing industry, a whole lot of data is available and continuously being generated which can help in predicting and even prescribing future possibilities/solutions to make this industry of utmost importance, more sustainable and can help in achieving global SDGs. Lowring carbon footprint of various important products of chemical manufacturing industry and making whole manufacturing process more energy efficient also needs technology intervention and leveraging it can help in achieving it as well as reducing development/innovation timelines.

Leveraging technology is a valuable tool with dealing with the more difficult problems. Defining the approach to choosing the right technology will lead to faster and more effective solutions. Driving to choose the simplest solution will allow you to achieve at the highest levels.

From what I've seen, leveraging technology is crucial for innovation in process design. Stay informed about emerging tools and platforms - they can often solve problems you didn't even know you had. I've found that automation software, AI, and data analytics can reveal inefficiencies and suggest improvements that humans might miss. Don't be afraid to experiment with new tech. Start small, pilot solutions, and scale what works. Remember, technology should enhance, not replace, human creativity. The best innovations I've witnessed combine tech capabilities with human insight. By strategically integrating technology, you can streamline processes, reduce errors, and free up time for more value-added activities.

Moderne Technologie bietet zahlreiche Werkzeuge zur Optimierung von Prozessen. Automatisierungstechnologien wie Robotic Process Automation (RPA) k?nnen repetitive Aufgaben übernehmen und die Effizienz steigern. Datenanalytik und Business Intelligence (BI) helfen dabei, Prozessdaten zu analysieren und Entscheidungsprozesse zu verbessern. Der Einsatz von Simulationstools erm?glicht es, Prozess?nderungen vor ihrer Implementierung zu testen. Cloud-basierte L?sungen und IoT-Technologien bieten zus?tzliche Flexibilit?t und Echtzeit-Datenzugriff, um Prozesse dynamisch anzupassen und zu optimieren.

Como puedes simplificar unproceso complejo? es facil, todo sale de la imaginación y conocimiento del proceso actual; tienes 5 lineas de producción con procesos similares? desarrolla solo una linea para 5 productos con la minima cantidad de equipos, utiliza herramientas lean, pero sobre todo, cumple los requerimientos del producto.

The fundamental approach is a step by step analysis of the product and creating individual process steps to complete the process flow. Assessing critical features or steps that could include tight tolerances and like features provide the opportunity to combine steps that can lead to reduced costs, and improved product quality.

In my experience, simplifying processes is often the key to innovation. It's easy to overcomplicate things, but true innovation often comes from stripping processes down to their essentials. I've seen teams achieve breakthroughs by asking, "What if we removed this step?" or "Is this really necessary?" Mapping out processes visually can help identify redundancies or bottlenecks. Encourage your team to challenge each step and look for ways to streamline. Remember, simpler processes are usually more efficient, easier to manage, and leave more room for creativity. Some of the most innovative solutions I've encountered came from radically simplifying complex processes.

Die Vereinfachung von Prozessen kann durch Prozessmodellierung und Workflow-Analyse unterstützt werden. Value Stream Mapping (VSM) hilft dabei, Verschwendungen zu identifizieren und die Wertsch?pfung zu maximieren. Der Einsatz von Kaizen-Prinzipien, die kontinuierliche Verbesserung und Effizienzsteigerung in kleinen, inkrementellen Schritten f?rdern, kann ebenfalls hilfreich sein. Methoden wie Lean Management und Six Sigma bieten strukturierte Ans?tze zur Prozessoptimierung und Reduzierung von Komplexit?t.

Una de las bases del pensamiento Lean Manufacturing es minimizar la carga en los procesos, para ser más prácticas en la ejecución y documentación sin perder la calidad en ello

Continuous improvement is the key for better process design. In chemical industry, process design at the beginning of a project (green or brown field) is mostly focused on proven OR good engineering practices coupled with timely commissioning and product out from the plant. But, problem starts when this initial design does not get timely review over the period of time which makes it less efficient and technologically outdated resulting in diminished profitability along with rising ESG concerns. That is why it is important that process design should be periodically reviewed and upgraded with respect to improved sustainability, energy efficiency, productivity and process simplicity to sustain competitive advantageous position in the market.

Ein effektives System für kontinuierliche Verbesserung sollte auf KPIs (Key Performance Indicators) und Performance-Management-Systemen basieren. Die Implementierung von PDCA-Zyklen (Plan-Do-Check-Act) bietet einen strukturierten Ansatz zur regelm??igen überprüfung und Anpassung von Prozessen. Feedback-Schleifen und Lessons Learned-Analysen sind wertvolle Werkzeuge, um kontinuierlich aus Erfahrungen zu lernen und die Prozesse weiter zu verfeinern. Ein Qualit?tsmanagementsystem (QMS) kann dabei helfen, kontinuierliche Verbesserungen systematisch zu dokumentieren und umzusetzen.

Continuous improvement is key to a successful organization and should include the input from everyone. Having a process without an effective change management process will lead to failures within the organization. Chaos is not a strategy and unmanaged change can lead to organizational failures.