Ricky Mainda’s Post

If you are in a management position and want to approach a specific process control and improvement challenge effectively, follow these steps: 1. Identify the Problem: Recognize operational issues affecting efficiency. 2. Gather Data: Collect relevant data for analysis. 3. Analyze Data: Use data analysis to identify patterns. 4. Set Clear Objectives: Define optimization goals. 5. Engage Cross-Functional Teams: Collaborate with experts across departments. 6. Implement Process Controls: Upgrade control systems as needed. 7. Continuous Monitoring: Install real-time sensors for data collection. 8. Simulation and Modeling: Develop models to optimize processes. 9. Optimize in Stages: Gradually apply improvements. ——————— Step by step: 10. Data-Driven Decision-Making: - Make informed choices using data. 11. Training and Education: - Train staff on new procedures. 12. Maintain Flexibility: - Adapt to changing conditions. 13. Performance Evaluation: - Regularly assess improvements. 14. Benchmarking: - Compare performance to industry standards. 15. Regulatory Compliance: - Ensure changes meet regulations. Wait 🤌🏼 Let’s take an Example Challenge: 👇🏼👇🏼 “Inefficient Cooling Process Leading to Warping in Extruded Aluminum Profiles" ✍🏼 1. Identify the Problem: Notice recurring warping in aluminum profiles during cooling, affecting quality and increasing scrap. 2. Gather Data: Collect data on warped profiles, including dimensions, alloy, speed, and cooling conditions. 3. Analyze Data: Use statistical analysis to find correlations with process variables. 4. Set Clear Objectives: Aim to eliminate warping while maintaining efficiency. 5. Engage Cross-Functional Teams: Collaborate with operators, metallurgists, and engineers. 6. Implement Process Controls: Upgrade cooling with advanced equipment and precise monitoring. 7. Continuous Monitoring: Install sensors for real-time temperature and dimension monitoring. 8. Simulation and Modeling: Develop a model to optimize fan positions and speeds. 9. Optimize in Stages: Gradually apply changes based on modeling, starting with a subset of production lines. ——————— Step by step: 10. Data-Driven Decision-Making: - Use sensor and trial data for informed adjustments. 11. Training and Education: - Train operators on new equipment and procedures. 12. Maintain Flexibility: - Adapt to changing profiles, alloys, and demands. 13. Performance Evaluation: - Regularly assess warping and scrap rates. 14. Benchmarking: - Compare performance with industry standards. 15. Regulatory Compliance: - Ensure changes meet safety and environmental regulations By following these steps, the plant can improve product quality and reduce waste due to profile warping during the cooling process. 🤝🏼 For further clarification, please feel free to reach out. ☝🏼😉 Regards, Kareem Moustafa Mohamed Senior Metallurgical Process Engineer Gulf Extrusion LLC. - Al Ghurair Group

I really enjoy reading, writing, talking, discussing about the industry (in general). From Food to Energy, from Automotive to Infrastructure, from Glass to Defense, I had the chance to be exposed to all those industries in the past 6 years since we founded Unikuaa Training and Consulting . From those customers and experiences, we've found our greatest success in two key areas: > Asset Management > Operational Excellence And within those two higher level concepts, I will be sharing more often about the following topics: > Operational Excellence: - Value Stream Mapping & Process Mapping - Kaizen Events & DMAIC method - Theory of Constraints (ToC) > Asset Management: - Maintenance Management & Strategy - Maintenance Planning & Scheduling - Root Cause Failure Analysis - Life Data Analysis - Lifecycle Cost Analysis - FMEA & RCM I will bringing some of those topics in infographics, sketches, videos or references where you can find more and detailed information about that topic. Let me know if you want to know more about a specific topic, and feel free to reach out. Let's make 2024 a phenomenal year! Unikuaa Training and Consulting UNTURNING STEEL TRACTIAN SMRP-LATAM: Society for Maintenance and Reliability Professionals – Latin American Affiliate Associação Brasileira de Manutenção e Gestão de Ativos - ABRAMAN Infotec Brasil CON A7

Process training in a metallurgical process plant is essential for an enormous number of reasons which are all beneficial and important to our plants. Some writers say; "if you think training is expensensive, wait and see the results of an untrained staff". These coming days i shall be outlining a few importances of staff training in a Metallurgical Process plant. Todays reason is Innovation and Adaptability. In a constantly evolving industry, well-trained employees are more adaptable to new technologies and process improvements. They can implement innovations that enhance the plant's competitiveness. A trained mployees is a positive and productive employee.

Is your training program equipped to handle the unique challenges of different operating procedures? 🎙 Tune in to this week's ProseraPod: "Ask Ron Besuijen," where Ron Besuijen shares the challenges associated with each of the 4 unique types of procedures. 🚀 Reach out to our Prosera team for personalized strategies to enhance your training programs and gain insights from industry experts. 🔔 Stay updated with our series for more expert advice on improving your operator training program! 🔔 👉 https://lnkd.in/guy6AKs3 #Prosera #ProseraPod #AskRonBesuijen #OperatorTraining #OTS #TroubleshootingTactics #ProfessionalDevelopment #IndustryExperts #TrainingInsights

"In the world of industrial machinery, the qualities that define a true professional are key to success. Whether you're working with heavy equipment, automation systems, or complex machinery, these are the attributes to look for: 🔧 Technical Expertise: An in-depth knowledge of industrial machinery is a must. 🧩 Problem-Solving Skills: The ability to tackle challenges and find innovative solutions is invaluable. 🛡️ Safety Knowledge: Prioritizing safety and adhering to protocols is non-negotiable. 🔍 Attention to Detail: The devil is in the details, especially when it comes to efficiency and safety. 🔩 Mechanical Aptitude: Understanding how the cogs turn in the machinery is essential. 🔄 Adaptability: As technology evolves, staying ahead is crucial. 🗣️ Communication Skills: The ability to bridge the gap between technical jargon and clear explanations is key. 🤝 Teamwork: Collaboration is the cornerstone of effective machinery operations. 📅 Project Management: For those in leadership roles, overseeing machinery projects is a core skill. 📚 Continuous Learning: The machinery industry is ever-changing; staying updated is essential. 🕒 Time Management: In manufacturing, timing is everything. 🤝 Ethical Conduct: Honesty and integrity are the backbone of operations. 🚀 Problem Prevention: Anticipating issues before they occur can save time and resources. 🎯 Customer Focus: For those in customer-facing roles, satisfying clients is paramount. 📜 Certifications and Training: Keeping skills sharp through certifications and training is a smart move. In the realm of industrial machinery, these qualities ensure that professionals are effective and dependable, contributing to the smooth operation of machinery and the success of businesses."

📈 Improve your manufacturing skills with Hofmann training courses and seminars on balancing technology! Precision and efficiency are crucial in modern manufacturing. Balancing as a key competence to achieve this requires specific know-how. We offer tailor-made training programs to help you and your team acquire the skills and knowledge to achieve first-class results. 🎯 Why get training? Balancing technology is evolving rapidly. To keep up to date with the latest knowledge or to learn the basics first, Hofmann offers training courses and seminars also with specific specializations. With practical examples and comprehensive seminar documentation, the events can be held at Hofmann's plant or on-site at your company. Both comprehensive training courses and individual seminars can be offered in various fields: 📚 Our range of training courses includes: - Balancing for application engineers - Optimization of balancing processes - Machine operation - Inspection of balancing machines - Maintenance of balancing machines 👩🏫 Our experts: Our training courses and seminars are conducted by experienced specialists who have extensive practical experience and in-depth knowledge. They not only provide theoretical basics, but also practical tips and best practices that can be applied immediately in your company. 👉 Get in touch with us: For more information and to register, visit our website https://lnkd.in/euhGvAjA or send us a message directly here on LinkedIn. Invest in the future of your production - with our training courses and seminars on balancing!

Process control, why train in this technology? Process control technology is widely recognised and used in industry. It is a set of techniques and systems used to monitor, control and optimise industrial processes in real time. Its main objective is to maintain process variables within predefined ranges to achieve safe, consistent and efficient results. In essence, process control technology seeks to maintain balance and stability in a dynamic system by continuously adjusting the inputs and outputs of the process to keep the defined variables at the desired values. This requires continuous feedback, where real-time measurements of variables are compared with reference values and corrective action is taken to maintain the process in an optimal state. Process control systems consist of components such as: *Sensors, to measure variables. *Controllers, to make decisions based on the information received. *Actuators, to adjust process conditions according to the controller's instructions. Why is process control technology important and beneficial to industry? Some key features of this technology are: *Automation: Process control systems can operate automatically, adjusting process variables without constant human intervention. *Accuracy and speed: Process control technology can respond quickly to changes in the process and adjust conditions to keep variables within desired limits with high accuracy. *Security: Helps ensure the safe operation of industrial processes by preventing hazardous or unsafe conditions. *Efficiency: By keeping process variables within optimal ranges, greater operational efficiency is achieved, and costs are reduced. *Adaptability: Process control systems can adapt to different situations and variations in process conditions. Process control technology is applied in a wide range of industries, such as food, automotive, energy, manufacturing, pharmaceuticals and many others, where its use is crucial to maintain stable and safe operations and to achieve consistent, high-quality production. Aware of the benefits and widespread use of this technology in industry, SMC International Training believes that the training of current and future process control technicians is essential. The IPC-200 system is ideal for the development of all industrial process control skills. It is a fully modular and flexible system that emulates a liquid production and bottling plant. The IPC-200 is constructed entirely from industrial materials so that the student is familiar with the elements they will encounter in their working lives. Find out more about the educational possibilities of the IPC-200 system!

Process control plays a vital role in ensuring the safe, efficient, and reliable operation of industrial processes. Operators are responsible for monitoring and controlling these processes to maintain desired operating conditions and meet production targets. Here are some key aspects of process control that operators should be familiar with: 🌟Process Variables: Operators should have a clear understanding of the process variables that need to be monitored and controlled. These variables can include parameters such as temperature, pressure, flow rate, level, pH, concentration, and more, depending on the specific process. Operators should know the normal operating ranges for these variables and be able to identify deviations from the desired values. 🌟Instrumentation and Sensors: Familiarity with the instrumentation and sensors used to measure process variables is crucial. Operators should understand the principles of operation, accuracy, and limitations of the instruments and sensors in their control system. They should also be able to troubleshoot and calibrate these instruments as needed. 🌟Control Loops: Operators should be knowledgeable about the control loops in their process. A control loop consists of a sensor, a controller, and a final control element (such as a valve or actuator). Operators should understand how these components work together to maintain the desired process variable within a specified range. They should be able to interpret the readings from the sensors and make adjustments to the controller settings as required. 🌟Control Strategies: Operators should be familiar with the control strategies employed in their process, such as feedback control, feedforward control, cascade control, or ratio control. Understanding the principles behind these strategies helps operators make informed decisions when adjusting control parameters. 🌟Alarm Management: Operators should be aware of the alarm system in their control system. They should understand the significance of each alarm and how to respond appropriately. Prompt identification and response to alarms can help prevent or mitigate potential process upsets or safety hazards. 🌟Safety Procedures: Safety is of utmost importance in process control. Operators should be trained in safety procedures, including emergency shutdown protocols, isolation procedures, and response to abnormal process conditions. They should be aware of potential hazards associated with the process and understand how to mitigate risks and protect themselves, their colleagues, and the facility. 🌟Process Optimization: Operators should be encouraged to actively participate in process optimization efforts. They should be aware of energy-saving opportunities, process improvements, and ways to minimize waste or emissions. Operators can contribute valuable insights based on their day-to-day experience with the process. 🌟Continuous Learning: Process control ..... Remaining text in Comment.........

what's additional process and management requirement training In ISO/IEC 17025, additional process and management requirement training refers to specific training related to the processes and management systems outlined in the standard. Here are some key areas where additional training might be necessary: 1-Quality Management System (QMS): Training on how to establish, implement, maintain, and continually improve a quality management system compliant with ISO/IEC 17025 requirements. This includes understanding document control, record keeping, internal audits, corrective actions, and management reviews. 2-Risk Management: Training on identifying, assessing, and managing risks associated with laboratory activities, including risks related to personnel, equipment, procedures, and external factors. 3-Measurement Uncertainty: Training on estimating and reporting measurement uncertainty according to ISO/IEC 17025 guidelines. This involves understanding statistical methods, calibration uncertainties, and sources of measurement errors. 4-Traceability: Training on establishing and maintaining metrological traceability of measurements, ensuring that measurement results can be linked to national or international standards. 5-Equipment Calibration and Maintenance: Training on calibrating and maintaining laboratory equipment, ensuring that measurements are accurate and reliable. This may include topics such as calibration intervals, calibration procedures, and equipment validation. 6-Data Integrity: Training on ensuring the integrity, confidentiality, and availability of laboratory data, including data collection, storage, transmission, and analysis. 7-Continual Improvement: Training on implementing processes for continual improvement, including monitoring key performance indicators, analyzing data for trends and opportunities for improvement, and implementing corrective and preventive actions. 8-Customer Service: Training on understanding and meeting customer requirements, including communication, handling of customer complaints, and providing accurate and timely test results and reports. 9-Legal and Ethical Requirements: Training on understanding and complying with relevant legal and ethical requirements, including regulations, standards, codes of conduct, and confidentiality agreements. 10-Health and Safety: Training on maintaining a safe and healthy work environment, including training on laboratory safety procedures, hazard identification, risk assessment, emergency response, and personal protective equipment. These are just some examples, and the specific training needs will vary depending on the nature of the laboratory, the types of tests or calibrations performed, and the expertise of the personnel involved. It's essential for laboratories to identify their specific training needs and ensure that personnel receive adequate training to perform their roles effectively and in compliance with ISO/IEC 17025 requirements.

"Root Cause Analysis" A Management lecturer was talking about "Quality". Lecturer : We all know Lord Ram went to spend 14 years in forest and Sita was kidnapped because of a "quality issue". Student : How is this anything to do with quality? Lecturer : Tell me why did Sita go to forest with Ram ? Student : Because she was his wife and respected his every decision. Lecturer : OK but why did Ram go to forest ? Student : Because his father Dasharatha told him to do so and he never disobeyed his father. Lecturer : OK why did Dasharatha send his son to forest ? Student : Dasharatha offered his wife (Kaikeyi) two boons , and she chose to make use of them in the future. And she wanted her son to be king, so on the day of Rama's crowning, she asked Dasharatha to send Rama to forest and crown her son; reminding him of his promised boons. Lecturer : So why did Dasharatha offer his wife two boons ? Student : Because during a military campaign against Sambarasura, the wheel of Dasharatha's chariot broke and and kakiye inserted her finger to hold the wheel in place. Touched by her courage and timely service, Dasharatha offered her two boons. Lecturer: Hence Proved. The quality of Chariot's wheel was not up to the mark .. leading to kidnapping of Sita...!!!! [So, using the "5 why" technique we see that Quality is very important and if the quality of Chariot's wheel was good, the Ramayana wouldn't have happened!]