The tools and methodologies that our process engineering specialists put into operation are applicable to all sectors and to companies of all sizes and can bring about such spectacular results as increases in productivity of over 30%, savings in machine changeover times of between 30 and 40% or stock reductions of 20%, all without the need to purchase new equipment, simply by eliminating operations that add no value (but do add cost) to the final product.
Improvement of production processes
PRODINTEC has developed its own diagnostic tool for the productive system of a company: GAP (the Spanish acronym for Advanced Production Management). This tool, combined with the carrying out of a Value Stream Mapping (VSM), enables a clear definition of the initial situation of the production system (defined as the set of organisational processes of the company ranging from when the customer places an order until it is delivered and the systematic procedures reflecting the situation of the factory at all times), objective measurement of current productivity, quantification of any possible improvement, the proposing of solutions (based on techniques and tools such as Lean Production, TOCs, 6 sigma , TPM, SMED, JIT, etc.) and the evaluation of the result after its implementation.
This consists in the design of new plant layouts or in the redesigning of existing layouts aimed at defining an optimal configuration that allows the elimination of a great deal of wastage (operations that do not contribute added value) associated with overproduction, downtimes, transport, processing, stock, movements, defects, etc.
Simulation of industrial processes
This analysis and complex system design tool can simulate the behaviour of a system under different circumstances and analyse potential changes and their consequences before carrying them out.
Simulation helps the user make informed decisions comparing different alternatives and reducing wastage before the start-up of the production line.
The simulation of workstations allows a detailed analysis of any job, optimising parameters such as distances and the location of resources and validating the set-up from the point of view of ergonomics.
We use this tool at PRODINTEC to analyse and validate new processes without having to resort to pilot workstations, demonstrating the operation of a manual process or workstation, training workers or reducing costs and times (time to market and time to volume).