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What are some tools for process engineering innovation?

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Process engineering is the discipline of designing, optimizing, and managing industrial processes to achieve desired outcomes. Process engineering innovation is the application of creative and analytical methods to improve process performance, quality, efficiency, and sustainability. In this article, you will learn about some tools that can help you with process engineering innovation, such as:

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Suresh Naik Korra

Senior Director & Head of Process Engineering at Sai Life Sciences Ltd | IIT Madras | ISB Hyderabad | Pharma 4.0 |…
Hyuin-Sun Cabrera Gonzalez

Jefe de Innovación e Ingeniería de Procesos en Molynor

1 Process mapping

Process mapping is a technique that uses diagrams, symbols, and text to represent the steps, inputs, outputs, and interactions of a process. Process mapping can help you identify the current state of a process, analyze its strengths and weaknesses, and visualize potential improvements. Process mapping can also facilitate communication and collaboration among stakeholders, as well as document best practices and standards.

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Suresh Naik Korra

Senior Director & Head of Process Engineering at Sai Life Sciences Ltd | IIT Madras | ISB Hyderabad | Pharma 4.0 | Industry 5.0
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Tools for process engineering innovation are: 1. Advanced versions of sophisticated process simulation software. 2. PAT tools to understand the process better. 3. Own designed standard calculation sheets or software applications for plug-and-play to speed up the decision making process. 4. Pilot scale-up kits based on the process understanding in lab to generate plant scale parameters. 5. Knowledge gained during troubleshooting in the plant scale operations and analysing and validating the data against simulation studies. 6. Standard charts and graphs for comparison.

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Adrian Howe

Partner at Marchington Consulting
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Use a large whiteboard with clear colour annotation. Keep it simple and accurate. It's collaborative and easy to keep up to date, without spending hours in front of a computer. I tend to use blue for process variables and overlap "post it" notes for their values. Red = out of control or unknown (with an action to fix) and green if in limits. If something is unknown or not measured I use amber with an action to find out. Actions with a who and when can also go on post its before transposing into an action log, if you need to do so for change control. Make sure your model reflect reality - check the detail out in the plant, as P&IDs can be out of date.

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Gustavo González

GESTOR DE PROCESOS DE NEGOCIO
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De acuerdo con mi experiencia se deben identificar los procesos desde un nivel Macro partiendo de lo general y focalizando gradualmente a lo particular y critico. El mapeo o documentación del proceso no tendrá un impacto para los colaboradores si la metodología no es amigable, es recomendable conocer la opinión de los directores y gerencias para obtener la mejor comprensión de la información plasmada. Posteriormente bajo mi experiencia la representación grafica del proceso a través del diagrama de flujo funcional es de de las mejores formas de mapear un proceso ya que establece las actividades y los departamentos o responsables que deben ejecutar la acción.

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Victoria Hebling Arroyo

Engenheiro de Processos | Engenheiro de Qualidade| Melhoria contínua | SGI
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El verdadero valor del mapeo de procesos reside en su capacidad para revelar conocimientos ocultos que pueden transformar la eficiencia organizacional. Al mapear procesos, no solo se pueden identificar fallos y cuellos de botella, sino también descubrir áreas donde se puede aplicar la innovación para simplificar y mejorar las operaciones. Además, el mapeo promueve una comprensión compartida entre los equipos, alineando a todos hacia metas comunes y facilitando la implementación de mejoras significativas y sostenibles.

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2 Process simulation

Process simulation is a technique that uses mathematical models, software, and data to mimic the behavior and outcomes of a process under different scenarios and conditions. Process simulation can help you test and compare different process designs, configurations, and parameters, as well as evaluate the impact of changes, uncertainties, and risks. Process simulation can also support decision making and optimization by providing quantitative and graphical results.

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Eje Meggison

Process Excellence Manager @ Shell | M.Sc., Business Process | SOX 404 | ERP | Project Management | Digital Transformation Expert | SAP Implementation Specialist
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There are several process engineering innovations which could help businesses improve operations. Among them are Microsoft Power BI, which can analyse process data and provide actionable insights, and Six Sigma, which focuses on reducing waste and enhancing process quality and efficiency. Additionally, businesses can benefit from implementing an ERP (SAP) system, which integrates various aspects of operations, including resources, inventory, human resources, and processes, for efficient planning and decision-making.

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3 Process automation

Process automation is a technique that uses technology, such as sensors, controllers, actuators, and software, to perform tasks and operations that would otherwise require human intervention. Process automation can help you increase process speed, accuracy, consistency, and reliability, as well as reduce human errors, costs, and waste. Process automation can also enable real-time monitoring and control of process variables and performance indicators.

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Adrian Howe

Partner at Marchington Consulting
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I've seen huge variations in "level of human intervention" from mass production of cakes/sandwiches to a self-learning programme running a plant at an oil refinery. Automation has to be appropriate to the product and business model. I was once involved in a renewables project where a critical step gave rise to significant quality, material yield and lost output issues. In order to automate, you have to understand the process dynamics through a mixture of detailed process observation, sound engineering understanding, appropriate data, supplier collaboration. Then aim to build a semi-automated pilot before going down the full capital route. Why supplier collaboration? If they aren't providing in spec, then your automation may not cope

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4 Process innovation frameworks

Process innovation frameworks are methods designed to provide systematic and structured guidance for generating, developing, and implementing process innovations. Design thinking is a human-centered approach that focuses on empathy, ideation, prototyping, and testing to solve complex problems and create value for users. Lean is a customer-focused approach that seeks to eliminate waste, increase value, and improve flow and quality in processes. Six Sigma is a data-driven approach that looks to reduce variation, defects, and errors in processes and achieve near-perfect quality. Lastly, Agile is an adaptive and iterative approach that enables fast and flexible response to change and feedback in processes.

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5 Process innovation culture

Process innovation culture is the set of values, beliefs, and behaviors that support and encourage process innovation within an organization. It can help create a positive and collaborative environment where process engineers and other stakeholders can share ideas, experiment, learn, and improve. Process innovation culture can also motivate and empower process engineers to pursue process innovation opportunities and overcome challenges. To foster this culture, it is important to have a clear and compelling vision that aligns with the organization's goals and strategy. Additionally, leadership should be supportive and inspiring, providing guidance, resources, and recognition. Teamwork should be diverse and cross-functional, leveraging different perspectives, skills, and experiences. Finally, learning should be continuous and feedback-based improvement and experimentation that embraces failures, risks, and uncertainties.

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Hyuin-Sun Cabrera Gonzalez

Jefe de Innovación e Ingeniería de Procesos en Molynor
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La particularidad de un Ingeniero de Procesos en Innovación, es que tiene la capacidad de entender los problemas desde la raíz, dada la constante interacción con el entorno, ya sea los procesos y las personas a cualquier nivel. Esto puede ayudar a acelerar los procesos de cultura de Innovación y generar credibilidad de nuestro trabajo.

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Adrian Howe

Partner at Marchington Consulting
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Agree that in most of what we do as engineers, ops leaders and improvement, we need to sell the why-how-what. Just saying it won't make it happen.

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6 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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What are some tools for process engineering innovation?

1

2

3

4

5

6

1 Process mapping

2 Process simulation

3 Process automation

4 Process innovation frameworks

5 Process innovation culture

6 Here’s what else to consider

Engineering Management

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What are some tools for process engineering innovation?

1

2

3

4

5

6

1 Process mapping

2 Process simulation

3 Process automation

4 Process innovation frameworks

5 Process innovation culture

6 Here’s what else to consider

Engineering Management

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