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Process Industries – Webinar archive

The Evolution of Lean - From Cars to Chemicals to Supply Chains and Beyond

What is known around the world today as lean began with Toyota in the 1950s. This presentation will give highlights from that evolution and give examples of how lean principles have been successfully applied to nontraditional areas of application: process industry manufacturing, supply chains and service industries such as healthcare.

 Advanced Embedded Technology Systems

The presenter will review recent developments in human machine interface technology (HMI) that enable data monitoring of industrial processes and communication of KPIs to management. The use of specialized software also will be discussed so that these machine output measures are converted into a database and real-time management reports of factors such as downtime and equipment performance.

"Randomness Kills" – or At Least Cripples

As with many industries, randomness is a fact of life in the process industries. However, the level of investment, the continuous nature of operations, and the hazards of many products and ingredients make it particularly important to properly address known variability – and develop robust systems that help us cope with the unexpected. This presentation will survey some approaches to analysis of operations with random events: probability calculations, simulation (discrete and continuous), Monte Carlo methods and stochastic modeling/optimization. It will also discuss when each is appropriate and point out limitations and pitfalls.

Maximizing Business Value of Production with Existing Assets

Most production/manufacturing operations fall short of utilizing all the capabilities of their assets in terms of achieving metrics important to the business. This webinar presents a practical solution to gain that unrealized value by applying an advanced supervisory control designed to complement existing process control systems. Existing process controls have included various approaches to regulatory control and several with various levels of supervisory control logic.

The Role and Importance of Leadership in Driving Change in the Process Industries

Lean changes can be instituted at any point in time to improve a company’s operations, but ensuring that those changes are sustainable requires creating a lean culture. What is a lean culture? A "culture" means "the way we do things around here." To create a lean culture, employees must understand not only what to do, but why to do it.

Product Wheels: Achieving Balanced Flow in High Variability, High Mix Operations

Operations managers have a number of critical issues to consider when setting a strategy for production scheduling.

Lean Manufacturing - How to Win and Sustain the Gains

The presenter will provide an overview of lean manufacturing principles, the implementation of lean techniques and discussion of case studies.

New Product Development (NPD) Philosophy & Methodology a Presentation

This presentation is designed for anyone involved in product or system development. It provides fundamental guidelines gleaned from real-world experience, and considers the complete set of issues that should be addressed at each stage of product development.

Improving Packaging Operations with Simulation Modeling

In difficult economic times, corporations have few positive cost reduction options that simultaneously improve operational performance. This webinar addresses how simulation modeling tools and lean principles are used to identify and evaluate multiple value improvement opportunities in a packaging production line in order to increase capacity and reduce the facility’s operating costs.

 Product Wheels and Inventory Planning

A product wheel is a sequence of products used to plan production – especially useful for operations with significant product transition costs and/or times. In a previous Process Industries Division webinar, Foster examined the reasons for using product wheels and some techniques for developing good product wheels. This webinar will address inventory estimation and planning strategies when using product wheels.

Which Continuous Improvement Methodology Should I Choose? The iTLS Story

The global position of American industry has been eroding for several decades. Efforts to stem this erosion, such as total quality management (TQM), Theory of Constraints (TOC), lean and Six Sigma, have not always been successful and have even been counter productive. This presentation addresses a tested and robust solution that has revitalized our industries effectively and simply. It involves a unique integration of the TOC, lean and Six Sigma methodologies, known as iTLS. The financial and other benefits of applying TOC, lean and Six Sigma together are significantly larger than applying the techniques separately.

Lean Techniques Applied to Packaging of Process Goods

The application of lean manufacturing concepts and practices to the packaging of liquid, solid and flake products will be described with examples taken from actual production lines. The use of lean methods like SMED, 5S, Visual Management, Package-to-Order and Product Wheels to improve packaging operations, resulting in lower inventories, greater throughput and higher customer service levels will be explained.

Value Stream Costing in Process Industries ("Accounting to See")

This webinar introduces Value Stream Costing as the way to quantify flow improvements and inventory reductions financially. A case study is shown to illustrate this approach.

Industrial Engineering Applications of Rapid Prototyping

Rapid prototyping (RP) processes have been in existence for less than 25 years, yet they are now considered an integral part of the product design and development process. However, RP processes also have many uses for industrial and/or manufacturing engineers that are less well known. This webinar provides the audience with an overview of the major types of RP processes used to make plastic, metal, and ceramic parts.

Recognizing and Managing Bottlenecks in Process Plants

This presentation will describe how bottlenecks typically manifest themselves in process operations, how to recognize them using Value Stream Maps, and how to prevent problems external to the bottleneck from further constraining production.

5S in the Process Industry 

This webinar discusses the lean manufacturing concept of 5S, including lessons learned based on industry research of those who have implemented the philosophy in the process industry.

Choosing a Process Improvement Path 

In the webinar, Mabrouk will discuss strategy for implementing Productivity Programs, the purpose of various tools available (such as lean, Six Sigma, etc.), and establishing a continuous improvement culture.

Determining Economic Production Quantities (EPQ) in a Continuous Process: A Case Study 

A basic decision every production facility must make is how much product to produce and how frequently to produce it. Typical production quantity models balance two opposing costs: changeover costs and holding costs. This EPQ case study goes far beyond balancing opposing costs.

Developing Product Wheels for Process Industry Operations

Many Process Industry plants and lines require product transitions that take significant time or are expensive - or often both.  Because of that, production is often make-to-stock and is scheduled using a product wheel - a set sequence of product campaigns that may vary in quantity but not very much in terms of production order.  This webinar will discuss some techniques for determining the optimal tradeoff between target product wheel length and total wheel transition cost.

Lean Pull Design 

Numerous manufacturing companies have utilized pull to produce tremendous cash savings. Tom Knight will discuss the challenges and best practices for implementing lean pull principles. He will show you how companies in various industries have freed up millions in working capital, significantly reduced inventories, and improved customer service by adopting lean and pull design.

OEE: The Good, the Bad and the Ugly (Lean and OEE) 

This webinar will explain the basics and definitions of OEE (Overall Equipment Effectiveness) and then delve into both the dangers and most effective uses.

Safety in the Process Industries 

This discussion will be build around the U.S. regulatory requirements for implementation of OSHA 1910.119, Process Safety Management. A review of the key requirements of the regulation will be made, including the technical, facilities and personnel activities. Additionally, steps necessary for successful implementation of a robust PSM program will be made. The discussion will include how PSM activities are used as a basis for achieving production and cost goals.

SMED in the Process Industries 

This presentation will describe the Shingo SMED (Single Minute Exchange of Dies) methodology and the analysis tools commonly employed to execute it. The presenter will then discuss the types of changeovers encountered in a process operation and the challenges they pose, and will describe approaches that have proven to be successful in dealing with these challenges. He will demonstrate the use of a Value Stream Map to determine where SMED can have the greatest benefit and will explain application of SMED in areas beyond product changeovers.

Sprint Team-driven Process Improvement Examples at The Hershey Co.

The Hershey Company's Continuous Improvement System uses Sprint Teams as a primary method of driving breakthrough improvements across its process-oriented manufacturing operations. The presentation will explain the Sprint team concept and the similarities/differences from a traditional Kaizen event.

TPM in the Process Industries

Total Productive Maintenance is part of the Lean Tool Set for continuous improvement. Process Industries capacities are heavily impacted from capital equipment and equipment reliability. In the current economy, any improvement in this initiative will have a tremendous impact in corporate cash flow. This webinar discusses the Lean manufacturing concepts of TPM, including implementation challenges, TPM metrics and an open forum to share best practices.

Understanding Process Improvement Tools 

Learn why process improvement begins with a focus on standard work and variability reduction, understand how to apply lean and other process improvement tools and what the major benefits of each are.

Value & energy Stream Mapping (VeSM) Case Studies for Process Industries 

This webinar will describe an approach used at CMTC that the authors call VeSM with case studies that illustrate expanded mapping and analysis assessments based on classic Value Stream Mapping principles to include energy and statistical process properties to identify more opportunities for achieving cost savings, greater energy efficiency (& less GHG) and improved product quality.

Value Stream Mapping in the Process Industries 

This presentation will describe Value Stream Mapping (VSM) creation in the context of a process operation, and highlight the additions and modifications required to completely describe a process line, whether it be a continuous chemical process, a batch process, or a more discrete process producing rolls of paper or bottles of ketchup. Several VSM best practices will be illustrated. The use of Takt as a rate parameter rather than a time parameter will be discussed. The effect of process yield losses on Takt will be explained.

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