Process Audit and Process Development
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Process Audit and Process Development
A process audit is a comprehensive review of each phase of the aluminium extrusion workflow to verify that standard procedures are being adhered to, quality benchmarks are achieved, and overall efficiency is optimized.
The audit aims to pinpoint opportunities for improvement, ensure alignment with industry regulations, and minimize operational risks.
What is a Process Audit?
Process Audit
Most extrusion plants know what is happening.
Only a few truly understand why it is happening.
A Process Audit is not an inspection of procedures or a checklist exercise. It is a detailed engineering assessment designed to identify the technical and operational factors that limit productivity, increase manufacturing costs and reduce process stability.
During the audit, I evaluate the complete extrusion operation—from billet preparation and die management to press performance, profile handling and production standards. Every recommendation is based on measurable data and practical manufacturing experience.
The assessment typically focuses on:
Process stability and variation
Extrusion Ratio (ER) optimisation
Press utilisation and production capacity
Die performance and die management
Process flow and material movement
Changeover efficiency
Hidden production losses using the WTI (Waste Time Insight) methodology
Quality risks and process capability
Opportunities for productivity and cost improvement
The objective is not to produce another audit report.
It is to provide a clear engineering roadmap that enables manufacturers to increase productivity, reduce waste, improve process reliability and achieve sustainable operational performance.
Boost Your Team with Aluminium Extrusion Training
Tailor-Made Manufacturing Training
Effective training should never be generic.
Every extrusion plant faces different technical challenges, production constraints and improvement opportunities. That is why I usually recommend starting with a comprehensive Process Audit before designing any training programme.
The audit identifies the real causes of production losses, process instability and performance limitations. Based on these findings, I develop a tailor-made training programme focused on the specific needs of your plant, your equipment and your production team.
Training may cover topics such as:
Extrusion process fundamentals
Process stabilisation
Extrusion Ratio (ER) optimisation
Die management and die performance
Press productivity and operational efficiency
Waste reduction using the WTI (Waste Time Insight) methodology
All training sessions combine classroom knowledge with practical shop-floor application, allowing operators, engineers and managers to immediately apply new skills in their own production environment.
The objective is simple: deliver practical knowledge that solves real manufacturing problems—not standard presentations that end when the training is over.
Process Development
Every manufacturing process has been designed—either intentionally or by years of accumulated decisions.
The difference between an average extrusion plant and a high-performing one is rarely the press itself. More often, it lies in how the entire process has been engineered, balanced and standardised.
I help manufacturers design production systems that are built for performance, stability and long-term growth.
My work starts by understanding how the plant really operates—not how it appears on procedures or production reports. I analyse product mix, production flow, tooling strategy, equipment capability and manufacturing constraints to identify opportunities for measurable improvement.
A typical Process Development project may include:
Manufacturing process design and optimisation
Extrusion Ratio (ER) strategy and optimum press allocation
Process balancing and bottleneck elimination
Die portfolio optimisation and die lifecycle management
Process stabilisation and standardisation
Production flow and material handling optimisation
Press capacity and productivity improvement
Changeover strategy and setup optimisation
Standard Operating Procedures (SOPs)
Manufacturing KPI development and performance monitoring
Operator and management training
One of the key areas of my work is ER optimisation. By aligning profile allocation with the optimum Extrusion Ratio, manufacturers can often improve press utilisation, reduce unnecessary tooling costs, increase productivity and postpone expensive capital investments that are frequently considered unavoidable.
Another important element is process stabilisation. Stable processes produce predictable results, improve quality, simplify production planning and reduce day-to-day firefighting. My objective is to minimise process variation and create manufacturing standards that operators can confidently repeat every shift.
Where appropriate, I also apply my WTI (Waste Time Insight) methodology to identify hidden production losses, non-value-added activities and improvement priorities. This enables companies to focus their resources where the greatest operational and financial benefits can be achieved.
Every recommendation is based on practical manufacturing experience gained over nearly 30 years of working with extrusion plants, production teams and international industrial projects. The objective is always the same: to build manufacturing processes that are technically robust, commercially efficient and capable of delivering consistent results for years to come.
Why Choose Me as Your Professional Audit Expert?
With nearly 30 years of international manufacturing experience, I help aluminium extrusion plants improve productivity, process stability and profitability through practical, data-driven engineering solutions.
My expertise goes far beyond a traditional production audit. Every assessment combines deep technical knowledge with operational experience gained from leading greenfield projects, production transformations and process improvement initiatives across Europe, Asia and North America.
I specialise in identifying hidden production losses and converting them into measurable business results. Using my WTI (Waste Time Insight) methodology, I analyse the entire extrusion process to reveal where valuable production time is lost and where the greatest improvement opportunities exist.
My audits typically focus on:
Extrusion process optimisation and stabilisation
Extrusion Ratio (ER) analysis and tooling optimisation
Die performance improvement and die portfolio optimisation
Press productivity and Overall Equipment Effectiveness (OEE)
Changeover time reduction and process flow improvement
Scrap reduction and recovery potential
Production capacity optimisation without major capital investment
Unlike many consultants, I don’t deliver generic reports. I work directly with production teams to identify practical actions that can be implemented immediately while also building a long-term improvement strategy.
Having led major industrial projects, equipment selection, plant start-ups and operational transformations, I understand manufacturing from both the shop floor and executive management perspective. This allows me to connect technical improvements with business performance, investment decisions and sustainable operational excellence.
My objective is simple: help manufacturers produce more, waste less and build stable, predictable processes that create lasting competitive advantage.
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Ready to Improve Your Manufacturing Performance?
Improving manufacturing performance is not about working harder—it’s about making better engineering decisions.
From independent Process Audits and WTI (Waste Time Insight) analysis to ER optimisation, process stabilisation and tailor-made improvement programmes, I help manufacturers transform technical challenges into measurable business results.
If you’re looking for practical engineering expertise rather than generic consulting, I’d be pleased to discuss how I can support your organisation.