MAESTRI specific elements of the management system
There are two main types of production process in manufacturing industry: continuous process (process industry) and discrete process (mechanical manufacturing). Continuous process is a process with continuity of introducing raw material to the environment of transformation and withdrawing completed product. Industry sectors that can be classified as continuous processes are: chemicals, synthetic fibres, oil refining, pulp, paper, natural gas processing, continuous casting of steel, synthetic fibres etc. Processes with individual or separate unit production like automobiles, furniture or toys are called discrete processes. These type of processes characterize by individual or separate unit production.
The main difference between process industry and mechanical manufacturing is the way of raw material transformation. In process industry raw material experiences a transformational change as it becomes a product, opposed to a reconfiguration change in mechanical manufacturing. Another significant difference between process industry and mechanical manufacturing is the manner in which the process of transformation occurs. In discreet manufacturing the changes that occur in the raw material so that it becomes a finished product are achieved by applying a direct touch either personally by operators (like in assembly) or by some tools or devices (e.g. cutting tool). On the contrary, in the process industries the raw material changes itself by applying the proper environment conditions.
The differences mentioned above cause that both types of manufacturing processes require different approaches to process improvement as well as Lean Manufacturing implementation and face different types of difficulties as well.
Generally continuous processes are more capital-intensive. That results from the higher dependence on machinery and equipment both in terms of the production process organisation and of implementing improvements. Improving availability of finished goods, flexibility and product quality can be achieved rather by mitigating machine problems than
by improving operators’ work by implementing such Lean Management techniques like e.g. 5S and workstation organisation.
Discrete processes are more labour intensive due to the fact that operators generate most added value to the process. Effective improvements focus on standardization of operators’ work for example by 5S which makes better results and has a wider range of application than in the continuous processes.
To provide relevant solutions to the specific conditions of process industries, the following methods and tools have been proposed: