Changes in LATITUDE…

I talked about “The Process Perspective” in the inaugural issue, 74 weeks ago, but have not talked about it much since. It is worthy of further discussion, so let’s think about it a bit.

A “Process Perspective” implies a vantage point for viewing and evaluating processes.

This vantage point is useful because it provides a reusable framework that can be applied to new situations.

This perspective evolves and changes (and hopefully improves) over time: hence the “changes in latitude”. Because we don’t have to “reinvent the wheel” each time we are working on a process, we can improve and get better and faster over time.

Process can mean either a new process straight from R&D or an existing manufacturing process. The framework applies to both situations.

This framework has six themes…

Theme #1

Shiny equipment can hide ROTTEN processes.

Beware of this; it has cost companies as sophisticated as Apple hundreds of millions of dollars. Be sure you know how the equipment serves the needs of the process. Evaluate manufacturability ruthlessly, early and often.

Theme #2

System building is foundational for repeated success.

Systems and checklists are imperative “no-brainers” for Process Excellence. Some useful systems to consider: Process Fundamentals Overview technical document, Ideal Final Result analysis tool to create a “stake in the ground”, “process window” framework and performance data, and, pilot scale process turn-up criteria.

Theme #3

Process calculations are vital for true understanding.

How many calculations are you doing to understand your process better? What have you learned from these calculations? Calculation areas of interest include: fluid mechanical considerations, heat-transfer considerations, mass balance, energy balance, and, transient performance and response times.

Theme #4

No data, no opinion.

This seems very obvious, but many times discussions about a process are long-winded and unproductive and without the source data being presented. Fresh data is always best, and replicates are useful and revealing. Measurement error must be quantitatively understood and managed.

Theme #5

Atoms and bits are very different.

It’s interesting how breezy and unconcerned people can be about the long and winding road between research and commercialization for a new process. Many of these people are spectators and have never been participants in high-stakes process-engineering efforts. Bits are reversible for negligible cost, atoms are irreversible and normally product must be re-made. Software and atom-based manufacturing are therefore completely different endeavors. Knowing your “circle of competence” can help protect against missteps in this domain.

Theme #6

Research - manufacturing tension.

Research is the conversion of money to ideas. Manufacturing is the conversion of ideas to money. Both have to happen to generate revenue from research activities. Both activities have many challenges, and a healthy and natural tension between the two is normal. Effective researchers listen to manufacturing concerns and help solve them.

---

CHALLENGE TO READERS

Please think about your process engineering projects over the past 5 to 10 years…

• Do any of the above themes ring true for you? Does this have any application to a current project?

• What themes are missing from the above list? Can you document your own organizations’ “Process Perspective”? Sharing this perspective with equipment builders should be very useful.

I’m interested in your “Process Perspective”, and how this topic resonates with you. I’d love to chat about it with you (508-410-8081) and learn what your insights and experiences are.

If you email me I’ll get back to you promptly, thanks.

All the Best,

Marty

---