Process Variability Audit /

If you use industrial fluids in your manufacturing process, then day to day process variability is threatening your OEE and driving costs in the wrong direction

Reduce Process Variability, Improve Plant Profitability

Though the source of this quote is not known, I think we all know it rings true. “We do not know, what we do not know”, and in a manufacturing context, if you do not know what variables are negatively impacting your quality, your costs and unnecessarily taxing your resources, your overall profitability suffers. Global competition and rapidly changing technology is making the need to know the drivers that both positively and negatively impact our operations more critical than ever before. Unplanned events, or wasteful preventative measures need to be eliminated, and the only way to do that, is to identify what factors impact the manufacturing process. Once the Key Performance Indicators that impact the operation are well understood, managements’ challenge is to systematically and cost effectively reduce the variability of those KPI’s. Manufacturing is dynamic and a large number of factors impact processes. Measuring the correct parameters, having timely and accurate data, the expertise to interpret it and timely corrective action is the key to driving up OEE and driving down cost.

Sump Distribution

The Process Variability Audit (PVA)

On any given day, fluid condition in your manufacturing process is in one of three places:
1) Target Zone: where the fluid is performing its designed function and costs are being managed
2) Event Zone: where one of the many properties of the fluid is outside acceptable limits and putting the process or personnel at risk of an event
3) Waste Zone: where plant practice is allowing fluid/waste/resource cost to be much higher than necessary.
By taking a snap shot of the facility, the Process Variability Audit provides a profile of the number of fluid systems in each of these three zones. World class companies are able to manage and maintain a high percentage of their systems within the target zone. In the interest of continuous improvement and cost reduction, the PVA is an excellent diagnostic to determine where efforts need to be made to take the process to the next step.

The Outputs

Our on-site assessment of your fluid systems combines fluid analysis, infra structure review, consumption and waste data compilation as well as current plant practice to put together an overall profile of your facility. We look at the factors that drive fluid and waste costs as well as analyse the fluids to identify how closely the fluids are managed to their desired control plan, and if the control plan includes many of the analyticals that impact process performance. The analysis is compiled and presented to management with a summary of current condition with any recommended improvements outlined.

Next Steps

We will follow-up with you to discuss your needs and define next steps. There is no cost for the audit for companies that qualify and are looking to implement world class solutions.

We look forward to evaluating your current Fluid Use Process to see how we can help reduce costs, manage risk and address any root cause issues that are negatively impacting plant productivity, process availability or product quality. Our methodical approach follows a defined business process to eliminate fluid condition variability and its impact on your plant. Contact us today.

If you would like more information about Process Variability Audit

Please provide your contact information and we will send more information to your inbox on whats involved with a PVA. Though each report is slightly different depending on our findings, we can send you a sample PVA reports available so that you have a better idea of the value each facility gets from understanding the fluid condition variability and its impact on your facility.