What Is Centerlining in Manufacturing Process and Why It Is Needed

In any manufacturing process, there is one big dream — to produce a consistent quality product with minimal cost and downtime. In reality, however, key variables are often unstable, equipment behaves unpredictably, and human error introduces additional process variables. In such conditions, an approach called Centerlining — a tool that allows standardizing critical machine settings — comes to the fore.

What Is Centerlining

Centerlining is a method of identifying and maintaining established process settings of equipment and technological processes — also referred to as a process centerline.

The main goal of the centerlining process is to reduce process variables and evaluate product quality. The essence of the approach is to determine the settings at which the process is stable and the products meet quality standards. This is often achieved through defining and adhering to equipment centerlined settings that fall within a specific acceptable range.

Simply put, it is a way to fix the optimal operating values for temperature, pressure, speed, and other important process factors to avoid variation and ensure repeatable results.

Production parameters should not be “floating.” Even minor deviations can lead to scrap, equipment stoppages, overconsumption of raw materials or quality degradation. Run-to-target (RTT) manufacturing helps ensure that processes operate at the desired performance level. A stable production process leads to less waste and higher efficiency.

Why is Centerlining Important?

1. Improving product quality: Reducing variation in the production process leads to more consistent product quality.
2. Cost reduction: Less scrap and rework means less material and production costs.
3. Increased productivity: Optimally tuned machines run more efficiently and require fewer stops for tuning. This directly contributes to improved machine efficiency.
4. Improved safety: Stable processes reduce the risk of accidents and injuries on the shop floor.

Advantages of Centerlining Implementing

This approach is actively used in Lean Manufacturing, Total Productive Maintenance (TPM) and Six Sigma systems.

• Process stability: Centerline settings help keep processes in an optimal state by educing variables and increasing predictability. Regular monitoring prevents unauthorized adjustments that could affect product quality.
  
• Improved quality: Less variation means less scrap and higher product quality.
  
• Saving resources: Optimal machine settings reduce energy and material consumption, while proper implementation of the centerlining process ensures consistent resource utilization.
  
• Increased customer satisfaction: Stable product quality leads to higher customer satisfaction and a stronger company reputation.

How the Centerlining Process Works in Manufacturing

Implementation of centerlining usually takes place in several stages.

Stage	Description
1. Data collection and analysis	At the first stage the technological process is analyzed: which important variables are critical, how they affect the output result, within what limits they can be changed. These can be: – Temperature; – Pressure; – Feed rate; – Gaps; – Humidity, etc. This step can be time consuming, especially when relying on legacy systems and manual methods. Teams may also analyze process data and evaluate historical trends. Tools like Gemba Walk and statistical analysis help identify the key variables.
2. Determination of optimal values	After analysis, the team determines the best settings. This is the “center”— the target settings that provide the optimal process balance between quality, performance and reliability of the equipment. For example: – Temperature: 190 °C; – Pressure: 3.2 bar; – Feed rate: 1.5 m/s. Engineers must determine precise parameters and avoid unnecessary adjustments that could disrupt the process.
3. Setting working tolerances	For each parameter, acceptable upper and lower control limits (UCL/LCL) are set around the centerline settings. This involves basically determining boundaries to prevent drift. Example: – Temperature: 190 °C ± 2 °C; – Pressure: 3.2 bar ± 0.1 bar. These tolerances define the acceptable range and are recorded in special Centerline Sheets. Engineers create limits that serve as a control standard.
4. Visualization and standardization	The target values and their tolerances are displayed using a centerline checklist, visual boards, stickers, and SOPs to ensure visibility and compliance. This allows operators to quickly check the process settings and monitor them independently, avoiding unnecessary adjustments.

Common Errors in Implementing the Centerlining Process

To make centerline management system work effectively, it’s important to avoid the following pitfalls:

1. Insufficient data collection. Without clear visibility into the process centerline, optimization is impossible.
   
2. Ignoring the opinions of operators. They often have firsthand knowledge of the process and machines and can provide valuable information. Frontline workers understand how different variables affect daily operations and can offer practical insights.
   
3. Infrequent inspection. Without routine centerline audit, all efforts will quickly come to naught.
   
4. Lack of visualization. If equipment settings aren’t clearly displayed, adherence becomes challenging.
   
5. Data overload. Managing and analyzing large amounts of data can be an overwhelming task without the right tools. The problems of manual data collection can be mitigated by using software to visualize and analyze the new centralized process.
   
6. Initial costs. Establishing a centerline management system may require investment in software and training.
   
7. Lack of expertise. Training is crucial to avoid unacceptable product quality.
   
8. Human mistakes and data error during logging and adjustments can undermine the entire newly centerlined process. It’s also important to ensure easy access to historical and real-time information to support decision-making.
   

Examples of Successful Centerlining Applications

Manufacturers across industries use centerlining to stabilize operations and improve results.

Production area	Description
Automobile industry	In the automotive industry, centerlining is used to adjust machine tools to produce parts with high accuracy and minimal deviations. This leads to reduced scrap and improved vehicle quality.
Electronics	In electronics manufacturing, centerlining helps maintain stable assembly and testing processes, which is especially important for complex electronic devices. This reduces defects and increases product reliability.
Food industry	In the food industry, centerlining is used to adjust machinery such as extruders and packaging machines to ensure consistent quality. This is especially important for meeting food safety and standards.

Case study: Centerlining Machines on a Packaging Line

Suppose a production line is used in a production facility. Before the introduction of centerlining, each operator set the parameters at his own discretion: sealing temperature varied from 160 to 180 °C, pressure — within a wide range. As a result:

• Packaging was unsealed or melted;
• Failures were as high as 10%;
• There were frequent stoppages and changeovers.

After implementation of centerlining:

• Optimal parameters fixed: 172 °C ± 2 °C, pressure — 3.0 bar;
• Settings were posted as a centerline checklist directly on the machine.
• Operators received training and the line was monitored via routine centerline audits.
• Rejection rate dropped by 60% in the first month, showing a positive effect and potential benefits.

The Role of Digital Tools in Centerlining

Digital tools for centerlining offer real-time monitoring, automatic alerts, and integration with analytics platforms (SPC, Six Sigma, KPIs). This enhances control and accelerates responses while helping to monitor critical process variables.

To enhance centerlining efforts, companies implement platforms like a connected worker platform to standardize communication and simplify decision-making.

In real conditions, the implementation of centerlining may require methodological support — from the collection of initial data to the preparation of visual materials and setting up the control system. Here, not only technical expertise is important, but also the ability to adapt the approach to the specifics of a particular production facility.

Companies such as ProcessNavigation specialize in implementing methods to improve operational efficiency, including centerlining. The company helps at all stages: from identifying critical parameters to creating visual Centerline Sheets and integrating the approach into the existing quality management system.

An important feature of such projects is the focus on sustainable results: not just setting up a process once, but building a culture of continuous compliance with optimal parameters and prompt response to deviations. With the help of a connected worker platform, real-time collaboration becomes more seamless and scalable across the shop floor. This approach recognizes that optimization is a never ending process that requires constant attention and refinement.

ProcessNavigation helps integrate centerlining in manufacturing through:

• Identifying critical process parameters and key variables.
• Defining optimal asset centerline settings.
• Preparing visual materials and centerline checklists.
• Setting up a centerline management system for continuous improvement.
• Ensuring alignment with upstream processes to maintain consistency across operations.

 Benefits of working with ProcessNavigation:

• Quick start: the team receives ready documentation and training.
• Transparency: all settings are visible, standards are fixed.
• Adaptability: From manual to digital centerlining.
• Support for change: help you adapt to new tasks.
• Sustainability: Ongoing centerline audit and monitoring.

Organizations that work with ProcessNavigation typically achieve the most benefits from their centerlining initiatives due to the comprehensive approach and ongoing support provided.

Centerlining is a powerful method to reduce variables, enhance quality, and cut costs. Its implementing requires careful planning, staff training and continuous process monitoring. With planning, training, and the support of digital tools, manufacturers can turn it into a foundation for continuous improvement in both process and product.

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