Process control and optimization

The aim of process segmentation and analysis is to identify, define, manage and control processes to ensure an efficient transformation of inputs to outputs with minimal resource consumption.

Therefore, we develop those processes that have the main impact on customer requirements and create added value and evaluate inputs.

Processes that do not add value, but are only support for evaluation processes, we will minimize.

The process analysis will then show us processes that do not create value, do not support the appreciation of inputs and are either completely unnecessary for the organization or even devalue inputs and resources deployed. We must minimize such processes resp. completely excluded.

How important are Key Performance Indicators (KPI)?

Example:

Annual production capacity output of the plant: 300 k cars

Number of parts in 1 car: 20 000

Number of critical parameters on one part (D/TLD, CC, SC…): 10

If the agreed target value is ppm 64 (Cpk = 1.33), it means that each manufactured car will have on average at least one production defect = one critical parameter out of tolerance.

At ppm 1 (Cpk = 1.67), on average 20% of cars will have one critical parameter out of tolerance.

At ppm 2, the production line produces only defect cars for two hours – 120 pieces (120 parameters out of tolerance).