Process Improvement and Optimisation
Process improvement and optimisation encompasses several techniques to ensure that a process performs as efficiently as possible while minimising waste. Some of the main aims of optimisation include maximising yields and product quality, minimising processing costs, and minimising defects.
Different techniques can be used at different stages of the process lifecycle, from design and development to mature processes. Process improvement and optimisation techniques and methodologies that we are experienced in include:
Design of Experiments
Design of Experiments (DoE) is a methodology that tests various factors in a process to determine which of the factors have an impact on the parameter being optimised. For example, if a company is trying to maximise yields in a chemical reaction, some of the factors that can be investigated include pH, temperature, and reaction time. By setting these factors at different levels and running a series of experiments at each combination, the optimum settings can be determined.
Lean Six Sigma
Lean Six Sigma combines principles of Lean manufacturing with the use of Six Sigma methodologies.
The primary goal of Lean manufacturing is to eliminate waste. Some examples of waste include defects in a product, over production of products resulting in the need for more storage before distribution, delays in process steps, equipment idle time, and unnecessary movement by operators.
The primary goals of Six Sigma are to improve product quality by minimising defects or process non-conformances, and minimising variability in processes.
Statistical analysis is used extensively in process improvement and optimisation. We have experience in the use of statistical process control software, including SAS JMP, MiniTab and the R language scripting. If you are looking to streamline, improve and optimise your manufacturing processes, please get in touch.