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PROCESS CONTROL
EXPRO NOVEMBER 2013
STAF HENDERIECKX
Centre for the Promotion of Imports from developing countries | May 27, 2010
2
PROCESS CONTROLWHY?
TO IMPROVE YOUR BUSINESS RESULT
RESULT DEPENDS ON SALES
SALES INVOLVES:1. PRICE2. DELIVERY3. QUALITY4. COMMUNICATION
Centre for the Promotion of Imports from developing countries | May 27, 2010
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PROCESS CONTROL
WHAT?
PROCESS
CONTROL
1. PROCESS
EXAMPLE
Centre for the Promotion of Imports from developing countries | May 27, 2010
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PROCESS CONTROL
WHAT?
PROCESS
CONTROL
1. PROCESS
* INVENTORY OF CURRENT PROCESS* NECESSITY OF EACH OPERATION* BOTTLENECK
* CLASSIFY OPERATIONS:
1. VALUE ADDING –CUSTOMER PAID
2. NON-VALUE ADDING – NOT PAID BY CUSTOMER
3. PROBLEM RELATED
Centre for the Promotion of Imports from developing countries | May 27, 2010
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PROCESS CONTROL
WHAT?
PROCESS
CONTROL
1. PROCESS
VALUE ADDING OPERATIONS
* INCREASE EFFICIENCY*
EXAMPLE: CONVENTIONAL LATHE TO CNC
EXERCISE
Centre for the Promotion of Imports from developing countries | May 27, 2010
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PROCESS CONTROL
WHAT?
PROCESS
CONTROL
1. PROCESS: VALUE ADDING OPERATIONS* INCREASE EFFICIENCY*
WIPTotal Out /min
Case 1 Basic production as is now36,00 3,00 42,00
Case 2 Efficiency before bottleneck30,25 2,75 49,50
Case 3 Efficiency after bottleneck30,25 2,75 46,75
Case 4 Efficiency bottleneck40,37 3,67 38,47
Output
Centre for the Promotion of Imports from developing countries | May 27, 2010
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PROCESS CONTROL
WHAT?
PROCESS
CONTROL
1. PROCESS
VALUE ADDING OPERATIONS
• INCREASE EFFICIENCY*
= INCREASE OF OUTPUT
IMPORTANCE OF BOTTLENECK!
Centre for the Promotion of Imports from developing countries | May 27, 2010
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PROCESS CONTROL
WHAT?
PROCESS
CONTROL
1. PROCESS
NON-VALUE ADDING OPERATIONS
* REMOVE THEM* * DECREASE TIME*
EXAMPLE
Centre for the Promotion of Imports from developing countries | May 27, 2010
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PROCESS CONTROL
WHAT?
PROCESS
CONTROL
1. PROCESS: NON-VALUE ADDING OPERATIONS - EXAMPLE
Centre for the Promotion of Imports from developing countries | May 27, 2010
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PROCESS CONTROL
WHAT?
PROCESS
CONTROL
1. PROCESS: NON-VALUE ADDING OPERATIONS - EXAMPLE
Centre for the Promotion of Imports from developing countries | May 27, 2010
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PROCESS CONTROL
WHAT?
PROCESS
CONTROL
1. PROCESS
PROBLEM RELATED OPERATIONS
• REMOVE THEM*
NOT POSSIBLE?
THESE OPERATIONS MUST BE TEMPORARILY!
Centre for the Promotion of Imports from developing countries | May 27, 2010
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PROCESS CONTROL
WHAT?
PROCESS
CONTROL
1. PROCESS
SET
Centre for the Promotion of Imports from developing countries | May 27, 2010
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PROCESS CONTROL
WHAT?
PROCESS
CONTROL
2. CONTROL
WHY?
INFLUENCES ON ALL ACTIVITIES
Centre for the Promotion of Imports from developing countries | May 27, 2010
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PROCESS CONTROL
WHAT?
PROCESS
CONTROL
2. CONTROL
WHY?INFLUENCES ON ALL ACTIVITIES
Centre for the Promotion of Imports from developing countries | May 27, 2010
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PROCESS CONTROL
WHAT?
PROCESS
CONTROL
2. CONTROL
CONTROL INFLUENCES
Centre for the Promotion of Imports from developing countries | May 27, 2010
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PROCESS CONTROL
WHAT?
PROCESS
CONTROL
2. CONTROL
CONTROL INFLUENCES
HOW?
1. WHERE ARE THE PROBLEMS?
2. WHAT IS THE RISK?
Centre for the Promotion of Imports from developing countries | May 27, 2010
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PROCESS CONTROL
WHAT?
PROCESS
CONTROL
2. CONTROL
CONTROL INFLUENCES
WHEN WE KNOW THE PROBLEMS, WE WILL HAVE TO PRIORITIZE THEM
WHY?
• THEY ARE HIGH NUMBER• WE CANNOT WORK AT ALL OF
THEM AT THE SAME TIME
Centre for the Promotion of Imports from developing countries | May 27, 2010
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PROCESS CONTROL
WHAT?
PROCESS
CONTROL
2. CONTROLCONTROL INFLUENCES
WHERE?
USE OF 5S-METHOD
1.METHOD2.MACHINE3.MATERIAL4.MAN5.MANAGEMENT
Centre for the Promotion of Imports from developing countries | May 27, 2010
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PROCESS CONTROL
WHAT?
PROCESS
CONTROL
2. CONTROL: USE OF 5S-METHOD
1. METHODALL INSTRUCTIONS AS WELL
PRODUCTION AS CONTROLLING
2. MACHINEALL EQUIPMENT USED, AS WELL PRODUCTION AS CONTROLLING AND MEASURING
3. MATERIALALL PURCHASED AND SUBCONTRACTED ITEMS
Centre for the Promotion of Imports from developing countries | May 27, 2010
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PROCESS CONTROL
WHAT?
PROCESS
CONTROL
2. CONTROL: USE OF 5S-METHOD
4. MANALL ACTIVITIES PERFORMED BY PEOPLE
5. MANAGEMENTALL MANAGEMENT DECISION ABOUT INVESTMENT, ACCEPTANCE OF ORDERS…
Centre for the Promotion of Imports from developing countries | May 27, 2010
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PROCESS CONTROL
WHAT?
PROCESS
CONTROL
2. CONTROL: USE OF 5S-METHOD
THE M-ITEM WITH THE HIGHEST PRESENCE, REPRESENTS THE WEAKNESS OF THE COMPANY
EXAMPLE
1. METHOD 35 % 12. MACHINE 15 % 33. MATERIAL 15 % 34. MAN 25 % 25. MANAGEMENT 10 % 5
Centre for the Promotion of Imports from developing countries | May 27, 2010
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PROCESS CONTROL
WHAT?
PROCESS
CONTROL
2. CONTROL
CONTROL INFLUENCES
RISK?
USE OF FMEA
FAILURE MODE EFFECT ANALYSIS
Centre for the Promotion of Imports from developing countries | May 27, 2010
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PROCESS CONTROL
WHAT?
PROCESS
CONTROL
2. CONTROLCONTROL INFLUENCES
RISK? USE OF FMEA
1.FREQUENCY2.DETECTABILITY3.CONSEQUENCE
4. RPN: RISK PRIORITY NUMBER
Centre for the Promotion of Imports from developing countries | May 27, 2010
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PROCESS CONTROL
WHAT?
PROCESS
CONTROL
2. CONTROL: CONTROL INFLUENCESRISK? USE OF FMEA
FAILURE EFFECT CONTROLFRE-
QUENCYDETEC-
TABILITYEFFECT RPN
Tool bit broken, part rejected
2 7 7 98
Damage machine 2 7 7 98Increased cost 2 7 5 70
Surface too rough Increased cost Visual 7 2 5 70Presence of flash Operator hurting Visual 5 2 7 70Presence of flash Increased cost Visual 5 2 5 50
MACHING A FORGING
Too high hardness
Certificate supplier / Incoming inspection
Centre for the Promotion of Imports from developing countries | May 27, 2010
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PROCESS CONTROL
WHAT?
PROCESS
CONTROL
2. CONTROLCONTROL INFLUENCES
WITH THE KNOWLEDGE OF:
1. WEAKNESS2. RISK
PRIORITY FOR CONTROLLING ACTIONS
Centre for the Promotion of Imports from developing countries | May 27, 2010
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PROCESS CONTROL
WHAT?
PROCESS
CONTROL
2. CONTROLCONTROL INFLUENCES
FROM HIGHEST TO LOWER PRIORITY OR WHEN A PROBLEM APPEARS:
1. LIMITS ON THE INFLUENCE2. IMMEDIATE ACTION3. ACTION TO PREVENT THE
NEGATIVE INFLUENCE IN THE FUTURE
Centre for the Promotion of Imports from developing countries | May 27, 2010
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PROCESS CONTROL
WHAT?
PROCESS
CONTROL
2. CONTROL: CONTROL INFLUENCES
1. LIMITS ON THE INFLUENCE* REJECTION LIMITS* OPERATOR LIMITS
Centre for the Promotion of Imports from developing countries | May 27, 2010
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PROCESS CONTROL
WHAT?
PROCESS
CONTROL
2. CONTROLCONTROL INFLUENCES
2. IMMEDIATE ACTION
WILL BE PART OF THE INSTRUCTION (WHAT IF…)
HELP FOR THE OPERATOR TO SOLVE A PROBLEM
CONSISTENTLY
Centre for the Promotion of Imports from developing countries | May 27, 2010
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PROCESS CONTROL
WHAT?
PROCESS
CONTROL
2. CONTROLCONTROL INFLUENCES
3. ACTION TO PREVENT THE NEGATIVE INFLUENCE IN THE FUTURE
TO INCREASE THE CONTROLABILITY FOR ALL PROCESSES
WILL DECREASE THE REJECTION / REPAIR RATE
Centre for the Promotion of Imports from developing countries | May 27, 2010
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PROCESS CONTROLRESULT
1. INVESTMENT
2. NEED AT LEAST 6 MONTHS
3. CONTINUOUS IMPROVING
1. INCREASE PROFIT BY INCREASING SALES
2. LEADS TO A HIGH CONSISTENCY OF PRODUCTION RESULT
3. WILL DECREASE THE WIP AND CONSEQUENTLY CAPITAL NEED
4. SAVING KNOWHOW OF THE COMPANY
