Increasing the productivity of teams while maintaining basically the same operating resources is one of the purposes of industrial process engineering. Many times, it is not necessary to invest in grandiose solutions to boost results. It is enough to identify the bottlenecks in the production chain, reorganize the corporate routine, and align the team with the new directions.
But in practice, it may not be that simple. Not surprisingly, this mission usually falls to the production engineers responsible for the plant. Besides keeping the group aligned, these professional specialists analyze the best way to optimize the available operating resources without unbalancing the company's cash flow.
Relying on technological solutions and alternative methodologies is fundamental for successful process engineering. Continue reading this article and learn more about it!
Industrial process engineering: what is it and how to put it into practice?
The pillars of industrial process engineering involve producing more, in less time, with better quality and reduced cost. It may seem impossible at first glance, but redesigning the ways of working can bring these results - sometimes even sooner than you think. However, you can't do it alone. The first point, then, is for the whole team to be engaged in the same purpose.
This can be done based on strategies that dialogue with the bottlenecks in your business, such as: eliminating waste, conducting more strategic negotiations, rearranging logistics, investing in more sustainable solutions, in short, whatever makes sense for your manufacturing context. All this, of course, doing the constant exercise of minimizing expenses and optimizing resources.
How important is process engineering?
The importance of thinking about industrial processes in a collective way is due to the fact that, in order to readjust a production chain, basically all sectors must be changed. There is no point in wanting to provide new working conditions for front-line employees if the company's top management does not support the proposed solutions because it does not see that the benefits will come in the long term.
In the same reasoning, there is no point in demanding speed in processes if the manufacturing environment does not offer favorable conditions to boost employee performance. Therefore, when it comes to process engineering, the best way to boost productivity is to reorganize each point of the production chain by changing the routine, adopting new methods and a lot of training.
What is the relationship between manufacturing productivity and industrial process engineering?
A few decades ago, it seemed really impossible to produce something in series and volume in an uninterrupted way. Not least because the transformation of raw materials still followed a very artisanal logic. With the advances brought by the technological revolutions, machines were replacing handcrafted work and speeding up production lines.
In this sense, the relationship between manufacturing productivity and industrial process engineering is intrinsically linked to technological advances. Today, in the context of Industry 4.0, for example, the reality is completely different than it was decades ago. The main gains include high performance machinery, lower consumption of operating resources, and high productivity.
What are the advantages of optimizing industrial processes?
The advantages brought by intelligent process engineering are not only related to team performance and machine evolution, as mentioned above. The benefits go beyond and permeate all sectors of industry, from management to the shop floor.
As the processes will be more evolved, the production line will be continuous, without losses due to delays or rework. In addition, the use of more sustainable resources helps keep the company's coffers balanced, which is essential for effective budget management. We have summarized the main benefits of this process:
- Less waste of operational resources;
- More assertive decision making in the factory;
- Maintenance of product quality standards;
- More integrated processes and aligned teams;
- Increased productivity and billing.
How can process engineering make the manufacturing environment more productive?
Now let's get to some practical tips for an efficient industrial process engineering plan.
Listing and mapping the processes
The first step is undoubtedly to list and map out in detail the manufacturing processes. This task requires time and dedication, but the results are certainly worth it. Defining exactly the priority of tasks in the production lines, the responsible teams, and the process flowchart is essential to avoid failures and delays in operations.
Identifying gaps and opportunities
Identifying bottlenecks is also a decisive point in process engineering. This is because the sooner signs of problems are identified, the faster failures can be corrected. Preventive maintenance is a practical example of this, as it avoids future problems caused by negligence or internal disorganization.
Developing improvement points
The detailed supply chain analysis - as well as the strategic mapping we mentioned above - not only organize the internal processes but also allow us to see points of improvement. Valuable insights can be gained through accurate analysis of the manufacturing process.
Some examples include reducing the use of certain inputs, automating certain tasks, and investing in more specific training for employees.
Implementing and tracking change
Finally, keep in mind that a process engineering operation demands constant follow-up. Only then can the manager validate the implemented strategies, adjust whatever is necessary, and replicate successful patterns. This is also very important from the point of view of employee feedback, which can bring new insights from individual performance improvements.
What is essential for the configuration of a more productive factory environment?
Below, we list some indispensable aspects of industrial process engineering in the configuration of a more productive manufacturing environment.
Management support
It is impossible to start any improvement project in industry if this effort is not collective, as we said before. Therefore, the first step to good industrial project engineering is to bring sectors and management together. When presenting a resource optimization project, for example, the professionals involved must come to management with a detailed plan of operations, what will be spent, and what the gains will be.
Just talking about changing practices and methods without presenting viable solutions will not convince management that a certain investment is worthwhile. On the other hand, when the arguments are relevant and prioritize the return of the facilities, there is no reason for the project to be disapproved. This applies especially to proposals for the purchase of equipment and the execution of sustainable projects.
Training of professionals
Changing the factory production methods without training the employees responsible for the tasks in each department of the company will not bring effective results either. Before putting into practice a new methodology, however intuitive it may be, it is necessary to focus on training the teams so that everyone remains aligned, engaged and motivated with the changes.
In addition, the employees' own experience in the sector can generate valuable insights for the readaptation of projects in search of the group's productivity. Remember: when it comes to industrial process engineering, the industry's human resources are much more important than the financial resources themselves, since the intention is to boost the production chain spending as little as possible of the manufacturing budget.
Investment in technology
Sometimes it is inevitable to turn to the company's cash flow to modernize production and boost employee performance. In this sense, it is necessary to be open to new technologies to understand what they can do for the company's revenues. Solutions that run on natural resources, for example, may even generate a certain implementation cost, but the return on investment is guaranteed.
Lighting and natural ventilation projects
Another pillar of industrial process engineering comes precisely from technology: the intelligent use of natural resources for a cheaper and more efficient production chain - as in lighting and natural ventilation projects, which use the sun and wind to bring thermal comfort and health to the industry at zero energy cost.
Do you know how a natural ventilation system works and how it relates to sustainability? Test your knowledge in our quiz and find out if you are prepared to take your factory to a more sustainable level!
The lighting systems with linear domes, for example, can maintain a well-lit warehouse - without the need for artificial lamps - for about eight hours of work. The ventilation projects with industrial blinds and lanterns combine thermal comfort and air quality in the factory, bringing constant renewal and elimination of pollutants.
Another advantage is that these systems are easy to install, require little maintenance, and boost energy efficiency in the plant. All these factors are essential in the production engineering of an industry, since the intention is to increase employee performance without increasing energy or other resource consumption.
In these cases, saving on electricity costs is the key to optimizing the company's cash flow and positioning it as a sustainable brand in the market. After all, industrial sustainability and manufacturing productivity are aspects that always go together when it comes to process engineering.
If you want to learn more about sustainable systems for industry, download our free guide on natural ventilation and learn all the principles involved in this practice!
