The importance of process optimization in advanced manufacturing

This month, we hear from? Joshua Bunz Research & Development Technologist with the Walker Advanced Manufacturing Innovation Centre.

In many manufacturing organizations, process optimization is something that can be overlooked or only looked at from certain perspectives.

According to Lari Numminen at Workfellow, “Process optimization is the systematic approach of analyzing and improving business processes to achieve maximum efficiency, effectiveness, and quality. The goal of process optimization is to continuously reduce waste, increase productivity, and ultimately improve an organization's bottom line.”

From my industry experience, delays and issues get noticed during projects, but deadlines need to be met and new projects start without any time for investigation. This leads companies to repeat mistakes and errors and creates unnecessary rework.

"At the Walker Advanced Manufacturing Innovation Centre (WAMIC), we provide opportunities to create multiple iterations of ideas in a cost-efficient manner to resolve the process issue fully." - Josh Bunz, Research & Development Technologist, WAMIC

Our advanced manufacturing team can walk through your facilities with fresh eyes to identify opportunities for improvement. A typical process improvement project follows these steps:

1. Goal identification: We begin by understanding what you are trying to achieve.
2. Current process analysis: We will use process mapping and data analysis techniques to understand the current state.
3. Refined process development: Working in collaboration we will propose and select improved process ideas.
4. Refined process testing: We will test and analyze the proposed solution to ensure it meets the identified goals.
5. Refined process implementation: We will provide you with the necessary knowledge and equipment to implement the successful refined process.

During the analysis phase we conduct activities such as creating process maps that allow us to identify wasted space or time, safety issues, causes for excess work in progress (WIP), and other lean manufacturing barriers. We will collaborate with you to create priorities and time estimations to inform your continuous improvement schedule.

From my experience, companies execute improvement ideas on the “do it right the first time” maxim because time constraints can be a large factor. But rarely are these ideas fully satisfied after the first try and ideas that did not work perfectly first time are put to the wayside, so no additional resources are spent. However, often process improvement requires an iterative approach to build, implement, analyze and refine the solution before an ideal solution is found.

At the Walker Advanced Manufacturing Innovation Centre (WAMIC), we provide opportunities to create multiple iterations of ideas in a cost-efficient manner to resolve the process issue fully. We can build off companies’ initial ideas/prototypes or start fresh to free up their resources. WAMIC can execute the iterative testing phase the right way, so your ideas don’t go to waste!?

Interested in learning more about WAMIC or participating in solving your process optimization challenge?

Explore WAMIC’s website, and contact?David DiPietro, Manager, Business Development, at?[email protected].