Process Analysis

What is Process Analysis?

Process analysis is the systematic examination of manufacturing processes to evaluate workflows, resources, and results. It uses data from data collection, such as process signals and production performance indicators, to uncover bottlenecks, error sources, or inefficient steps. The goal is to maximize equipment productivity and support standards such as IEC 61508 for functional safety.

Importance of Process Analysis in Production

In manufacturing, process analysis helps detect machine failures, process interruptions, or material shortages before they cause larger problems. It is the foundation for a preventive maintenance strategy and promotes quality optimization by uncovering causes of rework or scrap costs. Without thorough analysis, processes remain non-transparent, which endangers production stability and unnecessarily increases manufacturing costs.

Practical Implementation of Process Analysis

Process analysis begins with collecting data – such as through sensors or Manufacturing Execution Systems (MES) – and evaluating workflows like setup processes or material flows. Methods such as value stream analyses or flow charts visualize weaknesses, while optimized production planning translates the results into concrete improvements. Tools like Predictive Maintenance use the analysis to predict and avoid future problems.

Benefits for Production

Process analysis increases equipment availability by optimizing inefficient workflows and reducing production downtime costs. It lowers inspection costs through targeted quality controls and supports disruption management by clearly identifying problem causes. It also promotes manufacturing automation by showing where automation brings the greatest benefit. The result is more efficient, stable, and cost-effective production.

Technological Support

Manufacturing Execution Systems (MES) are central tools for process analysis as they provide real-time data and map processes. Process monitoring with sensors continuously captures information that is used for analysis. Software solutions such as simulation programs or data analysis tools help understand complex workflows and plan optimizations. These technologies make process analysis precise and action-oriented.

Conclusion: Process Analysis as a Path to Optimization

Process analysis is the first step towards efficient and stable manufacturing.

Through systematic investigations and the use of modern technologies, companies can improve their workflows and reduce costs.

Start with an analysis of your current processes and use the insights to take your production to the next level.