Great Processes: SO WHAT?

Having great processes is imperative for successful manufacturing. Robust manufacturing processes WIN. Interestingly, there are benefits to having great processes throughout the innovation cycle. Let’s look at these benefits from the perspective of the “process owner”. Please keep in mind: If a company owns capital equipment used for manufacturing, they are obviously a process owner. Even if you outsource manufacturing (particularly if you use a supplier who has shabby non-repeatable processes), you will still own the resulting problems that you will have to resolve with your customers.

---

The list below is the SO WHAT (or benefits) of having great processes, by innovation stage.

Stage I: Idea Generation (0-1 parts being made)

• Systematic approach to exploration

• Early examination of tradeoffs

Stage II: Determine Feasibility (1-2 parts being made)

• Reliably and consistently make samples

• Determine manufacturing feasibility “sooner rather than later”

• Systematic evaluation of research concepts

Stage III: Customer Prototypes (3-100 parts being made)

• Supply samples to customers that are consistent

• Reduce process risk by using “final” process and equipment

• Understand capability before full-scale manufacturing

Stage IV: Full-Scale Manufacturing (thousands of parts being made)

• Improve yields in existing processes

• Increase capabilities in existing processes

Stage V: Life-Cycle Management (tens of thousands of parts being made)

• Test impact of supply changes to reduce cost

• Identify cost-reduction opportunities

---

My main learning from this line of thinking has been that great processes have tremendous benefits and that they do not just “crawl out from under a leaf”. At world-class manufacturing organizations, they are relentlessly crafted and engineered throughout the innovation cycle.

---

YOUR CHALLENGE THIS WEEK

Please think about the innovation stage of your most important Process Stewardship efforts…

• Are you systematically crafting the process to produce a great process? What is the evidence of this?

• Are you working with and challenging the equipment group to help you craft great processes?

I’d enjoy hearing about your “process ownership” experiences. As always, please email me and I’ll get back to you promptly.

All the Best, Marty

---