Process Optimization aims to enhance efficiency and reduce costs by refining specific parameters within a process while adhering to critical constraints. This disciplined approach ensures consistency in product, service and meeting customer expectations effectively. The session emphasizes the utilization of the "Six Sigma methodology" for process optimization, which centres on minimizing variations and defects as its core principle. ​​

The process begins with setting clear optimization objectives, established through discussions with the core team. In the Measure phase, the current state of the feed mill process (AS-IS state) is carefully documented, and critical parameters (CTX) are identified for study. These parameters include:​

Critical-to-Process (CTP): Factors like batches per hour, throughput, and pressure.​

Critical-to-Quality (CTQ): Particle size, protein, moisture content, and degree of gelatinization.​

Critical-to-Cost (CTC): Energy costs, shrinkage, and spares costs.​

Critical-to-Safety (CTS): Injuries and accidents.​

In the Analyze phase, statistical tools are used to assess the current process's stability and capability, highlighting areas for improvement. During the Improve phase, methods like Root Cause Analysis, Cause-and-Effect analysis, and the 5 Whys are employed to identify the root issues and create a roadmap for achieving the desired future state (TO-BE state). Finally, in the Control phase, a robust control mechanism is established to maintain the optimized process, ensuring that efficiency is improved and sustained. The ultimate goal is to enhance animal performance and achieve sustainable profitability by continuously refining the process to meet or exceed customer expectations.​

Instructor Bio

Mr. Meenakshisundaram Kanagaraj is a freelancing consultant, technical trainer, and speaker on feed milling. He holds a Post Graduate Diploma in Digital Instrumentation and a Bachelor’s degree in Physics. He has worked for an instrumentation company, an auto ancillary components manufacturer, and a multinational animal feed additive manufacturer. He has successfully completed a course on Lean Six Sigma Black Belt by the American Society for Quality (ASQ) and a course on Fundamentals of Feed Milling Technology conducted by the American Feed Industry Association (AFIA). As a consultant, he is involved in new feed mill projects from design to commissioning. He has helped feed milling organizations improve quality and productivity.​