Production process assessment

To record &  analyse all dimensions of production operations:

• The production process
• Production schedule & scheduling
• Production human resource
• Material resource
• Autonomous maintenance of manufacturing equipment
• Facility and equipment maintenance or modification
• In process quality-control programmes
• Safety program & requirement (Safety procedure and guidelines; Safety records, etc.)
• Schedule adherence level
• Cost-effective level
• Production tracking and quality control systems
• Yield / loss during manufacturing processes
• Operational reports
• Continuous improvement activities (Shutdown time, Resource utilization, Inventory and cost control, etc.)

To optimize manufacturing capacity:

• To assess the existing equipment.
• To analyze data.
• To assess bottlenecks.
• To define what can be done to optimize processes, to improve flexibility and to increase capacity (pumps, manifold, storage, ….).
• To define what would be the cost associated and for which additional quantity with a focus on blending and filling..

To map out current process flow diagram and equipment layout of the plant.

Optimization of the production resources

To analyses volume forecast in different aspects, especially if some large identified SKU are produced in a different way, to support a mass balance & further calculation.

To develop process design for blending & filling:

• To analyze data to assess bottlenecks, and to define what can be done to optimize processes as well as to improve flexibility and to increase capacity (pumps, manifold, storage, ….) what would be the cost associated and for which additional quantity with a focus on blending and filling.
• To determine blending facilities, including reviewing blending techniques and calculating number and size of blending equipment.
• To determine filling facilities, including calculating filling capacity and number of filling machine; developing filling line preliminary configuration and arrangement of pigged line & manifold

To eventually reorganize the shop floor and the way the work is currently done in a context where two shifts  operation is the target, then to propose for a future organization design of the plant.

Warehouse process assessment

To record &  analyse necessary dimensions of warehouse operations (i.e. material input and output):

• Warehousing process
• WH human resource
• Safety program & requirement (Safety procedure and guidelines; Safety records, etc.)
• Cost-effective level
• Product tracking and quality control systems
• Operational reports

To optimize material storage capacity:

• To assess maximum bulk storage capacity.
• To define whether this storage needs to preferentially be dedicated to raw materials or semi-finished products.

Plant design

• To “walk the route” and develop process and frame work for the full study.
• To create, analyze, and optimize the many aspects of the plant design to clearly define which capacity level can be achieved with the available land resource (i.e. two pieces of land), what necessary equipment should be developed and newly designed.
• To coordinate with external parties to develop concept design.
• To coordinate with external parties to develop concept engineering design