Process standardization is the cornerstone of any improvement in the manufacturing industry. In this article we explain what this methodology consists of, what its benefits are and how you can use Mapex to implement it effectively in your factory.
What is process standardization?
Process standardization consists of the unification of procedures, methodologies and operations within a company with the objective of creating a reproducible work model and guaranteeing the defined parameters of quality and efficiency.
It is a methodology that has two stages. The first is documentation, which involves gathering data and ideas from the existing production process. The second is standardization, that is, the creation of written documents that will serve as work instructions for a specific production process.
For this last stage, it is important that you analyze the weaknesses of your production process, determine a target for improvement and figure out how you can achieve it.
Once you have generated the work instructions, make sure that your employees have easy access to it. Also, don’t forget that staff training and motivation play a very important role in the successful use of the standard.
Benefits of process standardization
Before addressing the role of an MES system in process standardization, let’s review some of its main benefits.
1. Minimization of quality problems in production processes
Standardization according to predefined best practices minimizes the risk of producing defective products. Reducing process variability makes deviations and non-conformities less likely.
2. Reduced time spent on labor training
Work instructions reduce the time spent training factory labor because they provide clear, detailed procedures for performing specific tasks, making it easier to learn and perform activities accurately from the start.
3. Creating a benchmark for future improvements
Process standardization serves as a benchmark for future improvements because it establishes a clear and consistent baseline from which to measure and compare changes, identify areas for improvement, and evaluate the impact of implemented modifications on overall process performance.
4. Pre-process automation phase
This methodology creates a framework that is essential before proceeding with process automation.
Automating a process involves scheduling specific tasks to run automatically, which requires a precise understanding of each step of the process. Without prior standardization, automation can be ineffective or even counterproductive by replicating a process that may be inefficient or inconsistent.
MES systems to standardize production processes in your plant
An MES solution like Mapex plays a crucial role in managing, monitoring and optimizing production operations. This platform can help you get the most out of process standardization in several ways:
- Setting production standards: an MES system allows you to define and set production standards for each process, including quality parameters, cycle times, material requirements, among others. This ensures that all operators work according to the same specifications and procedures.
- Procedural documentation: an MES solution facilitates the generation and distribution of detailed documentation of work procedures, operating instructions, checklists and other relevant information in a 100% paperless environment. This ensures that all employees have access to correct and up-to-date information at all times.
- Version control: with an MES system, it is possible to control the versions of procedures and related documents. This ensures that the most recent and approved versions are used on the shop floor, avoiding confusion or errors due to outdated information.
- Real-time process monitoring: an MES platform automates real-time data capture of production operations, allowing performance to be monitored, deviations from standards to be identified and corrective actions to be taken in a timely manner.
- Performance analysis: through real-time and historical data analysis, an MES system helps identify areas for process improvement, optimizing efficiency, reducing waste and increasing overall factory productivity.
- Integration with other systems: an MES system can be integrated with other systems such as ERP to share relevant information automatically, improving coordination between different areas of the company and ensuring data consistency.
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