Highlights…Year One

Robust manufacturing processes WIN. Period. Full stop.

Winning in this context means high profits, happy customers, happy operators, and happy shareholders.

If we agree that robust processes win, the question becomes “what’s the easiest and surest way to build trustworthy and robust manufacturing processes?”

I’ve been writing this newsletter for a year now about this very subject. This is issue 52. I thought it would be a good time for me to review the past year’s newsletters and a pick out some highlights.

So without further ado, my pick of highlights from the past years newsletters…

#1

The ROI for building great processes is compelling.

• For the 24 major process projects over my career, the average return on investment has been huge, 20X to 50X.

#2

The process is Invisible, unlike the equipment.

• Although the process is invisible, the fundamentals that make it operate must be understood. This will help make the process explicit and visible, a key step in building robust processes.

#3

Process Stewardship is vital.

• Research stakeholders should view process development as a coequal activity with equipment development and material selection. The stability and health of key processes in manufacturing operations must be understood at both statistical and engineering fundamental levels.

#4

The Equipment is NOT Enough.

• Apple found this out with their synthetic sapphire effort in 2014. The process was not ready for manufacturing, but they built the equipment anyway. Apple’s losses were significant (even for Apple), probably in excess of $500 million.

#5

Manufacturability Assessments…Early & Often.

• Manufacturability must be assessed ruthlessly and fearlessly for new processes and products, with criteria agreed to beforehand. This will help avoid the building of equipment that does not serve the process, aka expensive boat anchors.

#6

Boldness and Courage are musts.

• ”You have to have the courage to be different. You can never do anything better, unless it is different. That is an impossibility.” – Amar Bose

#7

Spectators Do Not Build Great Processes.

• Great and profitable manufacturing processes are built by seasoned participants, not by spectators. Figure out who are the process builders and who are the spectators.

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CHALLENGE TO READERS

Consider the highlights discussed above, and review your progress in building great processes over the past 1 or 2 years…

• Has this highlight list provoked any useful ideas to follow up on?

• What has been the ROI on recent projects? What are your yields and what opportunities exist for improvement? Knowing this information should be helpful to the business.

Thanks for reading this newsletter, I genuinely appreciate it. Call me (508-410-8081) and let’s discuss doing great process work.

If you send us an email, we will get back to you promptly, thanks.

All the Best,

Marty

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