Good process technologists are worth their weight in gold. It is their responsibility to take the approved concept product and trial it through factory processes until it is safely and accurately produced for the customer. Here are some top tips for running successful trials:
Tip 1: Organising factory trials - always complete trial request forms; pay attention to detail and give as much information as possible. This lets everyone know your aims and what you hope to gain from the trial. It also helps line managers to be prepared, which in turn, saves valuable production time.
Tip 2: Preparation - be organised down to the last detail before the trial starts and have every item ready to go into the factory. Draw yourself a hazard analysis critical control points process flow-chart of each stage of your product, from intake of raw materials right through to depot. It helps to identify critical points.
Tip 3: Raw materials - check deliveries as soon as they arrive before taking them into the factory and check all the parameters against specifications from suppliers.
Tip 4: Preparing samples - have labels and packaging ready before you start. Shelf-life samples should always be taken from the beginning of the production run (this tests the cleanliness of the line). Nutritional samples should be accurate to the exact gram and customer samples should replicate the concept sample as far as possible.
Tip 5: Packaging - always trial packaging items - never leave the pack fit to chance. Even when using repeat item stock, one small change in gauge or 1cm in measurement can make the difference between getting a good or poor pack fit.
Tip 6: Problem solving - if things go wrong and you don't know the answer to a problem, seek out the person who does, and never be afraid to ask for help.
Tip 7: Trial report forms - record the whole trial as accurately as possible. Highlight problems and further actions required at an early stage and ensure you send them to everyone involved with the new product.
Tip 8: Production staff - always talk to the staff working on the line, (not just the managers), these are the guys who run the lines day-after-day and can often highlight areas for concern or potential problems.
Tip 9: Pre-production trials - an air of calm, confident, efficiency is required. But, also have a sense of humour and try your hardest not to lose it. If the trial goes well, they'll all love you for it and if it doesn't, well, you'll always have time to put it right.