A Process Builders CHECKLIST

Robust processes win, as we have discussed before. Therefore, the question we are trying to answer is: what’s the easiest and surest way to build trustworthy and robust manufacturing processes?

A recurring and helpful approach/mindset is to strive to operate in a preventative rather than a contingent mode. Put another way, it is better to prevent problems than to react to them after they happen. The goal is to reduce the impact of luck and increase the impact of good decision-making.

In that spirit, I present the following checklist, to help us anticipate problems and avoid problems. A separate checklist is included for each step in the process for developing robust processes. This list is not complete or exhaustive, but it should provoke some useful planning and actions.

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Step 1:

Create manufacturable and scalable research concepts.

□ Conduct a Pre-Mortem on possible process problems

□ Conduct a process review by the process receivers

□ Conduct a systematic design analysis of the process using Axiomatic Analysis

□ Develop and implement an IP (Intellectual Property) protection plan

□ Do an IFR (Ideal Final Result) analysis to define the benchmark “perfect process”

□ Run the lab-scale process in “production mode” to surface issues

□ Understand life-cycle tradeoffs and develop actionable framework

□ Why does the process work/not work? Generate real data and theories and share findings.

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Step 2:

Minimize time from first prototype full-scale manufacturing.

□ Conduct ruthless pilot-scale mock manufacturing trial: this is a CRITICAL and VITAL STEP

□ Develop physics and engineering based process simulation tools: quantify fidelity with real world

□ Identify and engage receiver who will own production process

□ Iterate on the process, just like equipment iterations

□ Simulate plant operation using capacity simulation software tools

□ Start testing for 2nd application, in case first application fizzles

□ Test the impact of raw material changes (meaningful and bold changes)

□ Understand competitive position and verify differential advantages

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Step 3:

Engineer robust and trouble-free production processes.

□ Capability metrics such as Cp, Cpk,and Defects per Unit (DPU)

□ Define error-proofing and automated inspection strategy and methods

□ Define, via real and fresh data, the size of the “process window”

□ Negotiate spec relief/tradeoffs with customer to increase process margin.

□ Plan for the next product and the product after that

□ Process tracking software and measurements

□ Understand and incorporate operator’s concerns and suggestions

□ Visual management system development and deployment

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My main learning from the checklist above is just how much we can do to anticipate and reduce problems. This approach may not be glamorous, because problems avoided do not need heroic solutions or interventions. However, as seasoned process builders know, building robust processes is inherently difficult enough, and we need to be as smart as possible as we make decisions and take action.

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CHALLENGE TO READERS

Please think about your efforts over the past 5 to 10 years to develop new and improve existing processes…

• Which phase have you been you in? Step 1 or 2 or 3? Does the checklist remind you of things you need to act on?

• What would your own customized checklist look like? Can you incorporate this checklist into an internal best practices document to help improve future projects?

I’d like to know what you have learned about preventative rather than reactive actions. Please call me (508-410-8081) and let’s compare notes and learnings.

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

All the Best,

Marty

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