It has always been amazing to me, how different disciplines in engineering approach problems from a completely different angle.
In this example, a mechanical engineer talks about their definition of a process in control, vs a chemical engineer's definition.
Now in parts manufacturing, the definition of perfect control, is zero variability in the part being manufactured. Once a standard has been set, the goal is 100% quality, meaning 100% of the parts manufactured meet that standard.
And whats the best way to reach 100% Quality?
Take as much variability out of all your process as possible.
Due to the nature of the types of processes Mechanical engineers tend to design, they look to "engineer out" variability. They look to build processes so robust that they are set and forget. Set them up once and then let them run.
Chemical processes however tend to be more dynamic in nature. Process inputs like flow, pressure, temperature, concentration, pH etc. can change quickly and significantly. Therefore when a chemical process is considered in control, its being sampled, analysed, interpreted and corrected on an on-going basis. Its constantly being monitored and maintained in its efforts to deliver 100% quality.
It is our contention that most of the processes in a parts manufacturing environment are mechanical in nature. These are the core processes. The processes where the company has the in house expertise necessary to control the aspects that impact product quality. The core processes are where these firms look to build their competitive advantage and innovate.
The problem is that there are a small percentage of the processes that are more chemical in nature than mechanical. These need robust process control solutions vs the more stable processes mechanical engineers are used to dealing with.
So where does Zimmark come in?
We are a bunch of chemical engineers that bring a unique chemical engineering approach to a predominantly mechanical engineered world.
We focus on the non-core chemical processes where inputs like pH, concentration, alkalinity, etc can all have a detrimental impact on part quality or total process cost.
By bringing a unique perspective and focus, we can help parts manufacturers reduce their costs and improve their OEE.
Curious if there is an aspect of your manufacturing process that needs a chemical vs mechanical mind set?
An area where maybe not all the process inputs have been identified and their variability is the root cause to aspects hurting your OEE?
Zimmark's Process Variability Audit looks to identify control problems in some of the processes that may not be on your radar as the root cause to quality, availability or excessive cost/waste problems.
Where there's smoke, there's usually fire, so a process where the inputs are highly variability can often be the source of the problem silently impacting plant OEE.
Sign up for your Process Variability Audit today, to find out if a bunch of chemical engineers can help you keep variability out of your manufacturing process.