Process Optimization

Growing competition in ceramics production is forcing all producers to find lower-cost production routes. With the Output Accepted Process (OAP) method developed at FGK, specific measures are taken to optimize existing production processes and to activate and embed internal company experience in process management.

At all stages from receipt of raw materials to final inspection, the potential for optimization is revealed and rapidly implemented.

Let our experienced FGK experts help you with this challenging task. Numerous large and small companies have profited from our approaches to considerably reduce reject rates, increase energy savings, and improve production reliability.

OAP means optimizing existing production processes by:

• Lowering the reject rate.
• Creating a reliable testing concept.
• Defining raw materials and product specifications.
• Optimizing communications between departments and with suppliers.
• Strategic development work and project Management.

Determination of the potential along the process chain through:

• Thorough stocktaking in the production process.
• Identification of the starting points.
• Identification of the relevant control parameters, including definition of fluctuation tolerances.
• Preparation of a list of measures.
• Implementation of the optimization measures with the Client.

The tools for process optimization are:

• Testing and analysis methods for improving process control (measurement system analysis, tolerance limit determination, and disturbance variable analysis).
• Use of Design of Experiments
• Introduction of statistical aids (SPC) for reliable control of the production process.
• Creation of closed control loops based on simulations, improved sensor technology, or model-based control.
• Introduction of quality assurance agreements (QAAs).