Continuous Process Definition
By definition, a continuous process means something which works without stopping the ongoing work, and usually, it does not come as batches generally .
Continuous Process are very common in the manufacturing industry, even though some parts of the world do not prefer to have this types of long Processes to their industries due to high labor costs and labor laws.
Continuous Improvement, which is known as the kaizen, can see as an improvement methodology in the modern context. If any organization needs to have a better process, having a kaizen methodology placed is a must.
5 Principles to follow
The principles to focus on having a proper continuous process would be as follows;
1. Having the required durable machines to have a long-hours of work for continuous process
Many machines in industries design to use for long hours. Due to that reason, it is essential to have devices that are capable of such an continuous process operation. Purchasing machines for a little cost will not be wise, and getting the right tools is the important thing here. From my personal experience, I prefer Europe based types of machinery; even the capital cost is high for it.
2. Proper Total productive maintenance (TPM).
Total productive maintenance is an area that can save a lot of money to the organization if it does correctly. From my experience, I have seen that some technical people do conduct the TPM for every machine by using the same cycle, which is wrong since some machines may need to have service in short intervals, and some may not. Therefore, planning the TPM according to the machine type for a better Continuous Process will be a key.
3. Defining the shift basis for workers in an efficient way
Basically, a conventional shift is eight hours long. And During this period. An organization expects its workers to work smoothly in a continuous process during this period. But a production process will not only be working the eight long hours continuously. The workers must have breaks and, more importantly, must have hourly targets defined according to the taken cycle times.
4. Product changeover understanding with respect to planning for continuous process
Some companies do have different product ranges. Therefore, an ongoing process must stop for some time for a changeover. The changeovers are time killers. The planning department in an organization that has varied product types should optimize the orders for better Process.
5. Labor laws in the country and overtime payments
Hence, People describe this part is a somewhat Human resource management related thing. But having a production process without concerning the law will pay severe consequences. A continuous process must adhere to all the labor laws and make sure to pay the payments to its workers accordingly. In times like a global economic crisis like the Coronavirus, it would be hard to maintain a good cash flow to give the payments.
You can read my other article on continuous improvement in here: Why Continuous Improvement Can Always Benefit