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Smart Operations: What is Process Optimisation?

Process optimisation is all about producing more with less. It involves enhancing the efficiency of processes by minimising the resources needed, reducing costs and maximising throughput.

Digital Transformation Guide



Your 5-Step Framework for Success

Changing existing processes creates an opportunity for growth. For a smooth transition, companies must follow a structured framework.

The first step is to identify an area that needs improvement. This can be done through observing current processes or analysing statistics that may flag where an intervention is needed.

Examples of this could include situations where costs are too high or processes aren't meeting business targets.

Why isn't the process performing as well as it should be? To find the problems, look at these three areas:

  • Equipment: Check if all the tools are working properly
  • Operating procedures: Review the current workflow of tasks
  • Control loops: Analyse the feedback systems 

This step is about positive change. Reformulation involves reshaping existing processes so they can become more effective. This can be done through extra training for staff, new machinery upgrades or building entirely new procedures. 

Rolling out the solution in the real-world is the true test. This phase reveals how well your team adapts to the changes and highlights what work still needs to be done.

Updated work instructions and augmented processes will likely be needed during this stage to ensure seamless onboarding of new procedures.

The key to determining the success of smart operations is to measure performance before and after the implementation.

It’s important to analyse data from various aspects of the company, including all production lines, to ensure the rollout hasn’t negatively impacted other areas.


How Do Smart Operations Boost Efficiency?

Investing in smart operations transforms ways of working, leading to more streamlined operations.
Here are two main areas to consider when making the change.

B

Connected Assets

Connected devices, particularly through Internet of Things (IoT) technology, provide companies with valuable insights into machine performance.

Fitting machines with sensors generates a wealth of performance data, including information on potential faults and wear and tear. This data-driven approach enables users to fix problems before they arise. Access to these insights saves companies time and money by reducing product downtime.

A

Digital Supply Chains

Product Lifecycle Management (PLM) is a key tool manufacturers use to create digital supply chains. This strategy focuses on all parts of a company's operations, breaking down each process within the chain rather than looking at operations as a whole.

This step-by-step approach allows for efficient improvements to be made across the entire supply chain.

Digital Transformation Guide


2 Strategies to Boost Your Output

Lean Six Sigma is a method used to improve company performance. Using these two approaches will help to reduce operational waste and process defects.

Lean

Lean is a framework for removing inefficiencies or ‘waste.’ It's all about doing things quickly and making the most efficient use of labour, materials, machinery and time. Resources that don’t add value are counted as unnecessary.

Six Sigma

This method is about doing things right. It aims to reduce product defects and inconsistencies in manufacturing. Six Sigma calculates error rates by recording the number of defects per million opportunities. A low level of defects per million opportunities indicates a high level of quality.

Embracing Digital Transformation

There's more to digital transformation than simply implementing new technology. Setting clear goals, focusing on key benefits and creating a digital-friendly culture will set your company up for success.

Discover 5 steps