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Integrated Process Management

The purpose of Integrated Process Management is to consistently control production variables to achieve higher quality, less scrap, and greater on-time delivery.  Integrated Process Management  is described in the book by the same name, written by Roger Slater. Phil has helped companies successfully implement IPM in a variety of industries, including electronics manaufacturing, food, chemical and process.

  • Two-day course
  • Taught at your facilities
  • Learn the six-step Integrated Process Management model described by Roger Slater in his book by the same name
  • For executives and operations management
  • Learn to improve processes and reduce variation without front-end loading with massive statistical training
  • Focus on getting improved business performance

“I enjoyed the session immensely. It was a chance to re-learn some items. I especially enjoyed the knocker exercise. It effectively illustrated process control. As an aside it was also an excellent team building experience. Rick Waugh, Engineering Manager , Omya Canada Inc.

The principles of IPM are:

  1. To lay strong foundations for a proactive, disciplined, data-driven process control system that empowers workers to take control of their production processes
  2. To identify those variables that must be carefully controlled to achieve high quality. We call these “Key Input Variables.”
  3. To develop “control standards” that describe how to control the key input variables. Process engineers develop these cooperatively with production managers and workers.
  4. To communicate the control standards to all workers and production managers who will use them or who will monitor their use
  5. To monitor the Key Input Variables on charts (done by operators) and to monitor operator adherence to the control standards and provide them with constructive feedback and reinforcement (done by production managers and others).
  6. To identify improvements in any of the above five points that will achieve higher quality by analysing the process in detail.

Course Agenda

Step 1: Create The Environment

  • How To Create The Positive Environment

Step 2: Identifying KIVs And KOVs

  • Identifying Key input variables (KIVs) And Key Output variables (KOVs)

Step 3: Write Control Standards

  • Control Standards For KIV Variables
  • When To Adjust A KIV?
  • The Process Control Standard

Step 4: Communicate The Standards

  • Additional Training

Step 5: Monitor And Provide Feedback

Use Of Control Charts And Run Charts

Role Of The Line Monitoring System

Step 6: Analyse And Diagnose Performance

  • Auditing
  • Criteria For Functional And Effective Systems
  • When Do Set Up A (Statistical) Process Improvement Project
  • The Process Improvement Cycle
  • Implementation Planning