Methods and apparatus for the testing, monitoring and improvement of manufacturing process effectiveness

A method of improving the efficiency of a manufacturing process, comprising the steps of:

• a) constructing a simulation model of a manufacturing process;
• b) collecting relevant static dynamic, and control data from a real manufacturing process;
• c) identifying and quantifying objectives;
• d) calculating a first value of complexity of the process according to the formula for calculating the index of complexity H;
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• e) calculating a second value of complexity of said manufacturing process according to said formula for calculating the index of complexity H;
• f) comparing the difference between said first and second values of complexity with a predetermined difference limit;
• g) modifying said simulation model according to whether said difference falls outside or inside said predetermined difference limit;
• h) checking a validated simulation model against said identified and quantified objectives;
• i) selecting an option from a predetermined hierarchial list of options;
• j) modifying said simulation model with said selected options;
• k) calculating values of complexity and consistent elements of the modified process simulation model using said formula for calculating the index of complexity H;
• l) checking whether said identified and quantified objectives are met;
• m) modifying said real manufacturing process in accordance with said modified simulation model.