Integrated Technologies, Inc. (ITI) has supported our clients on hundreds of projects to improve processes. Projects include process troubleshooting, opportunity assessments, compliance audits, pollution prevention studies, continuous improvement planning, value stream mapping, kaizen event facilitation, and implementation of SPC and six sigma methodologies. ITI utilizes proven methods and process modeling software to support our process improvement projects. We bring significant theoretical and operational knowledge of chemical processes to process improvement projects, and we can validate improvements with process laboratory support and development of methods and procedures. We specialize in optimization of material handling and process flow and smart integration of environmental, health, and safety systems.
Integrated Technologies, Inc. (ITI) has audited hundreds of surface finishing facilities over the past 28 years; inevitably we find that actual process procedures vary between operators, shifts, and with production demands. Process Documentation is often written to comply with customer or third party specifications; therefore, many companies miss a critical opportunity to improve their processes by not writing effective process procedures. These process procedures should be designed to instruct not just to comply. Effective process procedures and documentation can include process rules to error-proof processes and/or automate corrective action. Effective process procedures can also reduce supervision requirements. ITI will audit your facility and develop and document effective process rules and procedures.
Process Modeling & Mapping
Process Modeling is an extremely effective process engineering tool for optimizing complex processes and systems. Surface finishing facilities are complex systems; small process changes can impact water, energy, and material usage, labor requirements, dilute and concentrated waste streams, ventilation, and air emissions. Integrated Technologies, Inc. (ITI) has also developed Plato’s Process Planner™ (PLATO) to model process water, chemical, material, energy and labor usage, and environmental costs and to generate activity-based cost and other process reports, in order to prioritize process improvement. PLATO models process rinsing, solution dumps and bleeds, material usage, ventilation, waste streams, and air emissions. Process Modeling facilitates visualization of process relationships that would otherwise be hidden.
Process Mapping facilitates visualization of process relationships. ITI utilizes process mapping to evaluate process adjacency and workflow and to visualize value streams (value stream mapping). ITI also maps production sequences (production sequence diagrams), process flow (process flow diagrams), and process rules (logic diagrams). Process mapping is an essential process engineering tool.
Make vs. Buy Analysis
Over the past few decades, manufacturers have focused on core competencies in their manufacturing operations. Surface finishing operations have often been scrutinized for both outsourcing and insourcing opportunities. Many companies outsource some surface finishing but also have internal operations for critical processes where they possess intellectual capital. Outsourcing is never an all or nothing commitment. Integrated Technologies, Inc. (ITI) has worked with many companies to evaluate their surface finishing requirements, supply chain, and/or operations to assess the feasibility of outsourcing or insourcing surface finishing. ITI can help your company evaluate opportunities to improve your business with a Make vs. Buy Assessment.
Activity Based Cost Analysis
Integrated Technologies, Inc. (ITI) has developed advanced Activity Based Cost (ABC) analysis and reporting capabilities for surface finishing processes and operations. ABC analysis builds off our Process Modeling capabilities. We can help you visualize process or part specific labor, material, energy, and environmental costs, and evaluate profitable and unprofitable processes and programs or jobs. ITI can develop process models of supplier processes, as well, and determine lowest achievable cost for specific processes or parts. ABC analysis can help you prioritize improvements, rationalize outsourcing or insourcing decisions, negotiate reduced supply chain costs, and develop hedging strategies to manage volatile material and energy costs. ITI can help your company evaluate opportunities to improve your business with an Activity Based Cost Assessment.