Production process technology conversion

•  Problem / Situation:

The client had successfully completed development trials of a new chemical process to replace outdated chemistry for a high volume consumer product. The new process had huge potential for increased productivity and process reliability as well as being more environmentally friendly. However, there was high production demand for the existing product and the only downtime windows were a long weekend and two one-week shutdowns during the summer. Three production lines were involved. The challenge was to make a seamless technology conversion, achieving full production capacity with minimal ramp-up time and with no loss of product shipments.

•  Solution and Approach:

There was a significant engineering component to this project requiring mechanical, hydraulic, instrumentation, electrical and control systems expertise. Apogee Management Group provided much of the direct expertise needed and managed the full complement of additional internal and external resources that supported the engineering requirements. Specifications were required for site preparation and foundation installation to accommodate new equipment. New equipment systems were specified, designed and approved. Detailed component layout and piping design was required to integrate existing and new process equipment. Control systems and software had to be revised, upgraded and integrated with existing systems.

 A strong project management structure with heavy emphasis on schedule development, communications and performance reporting were crucial to the project success. With tasks being scheduled by the hour, risk management was critical in identifying uncertainties that could disrupt the project plan. For example, a special backup supply system for the chemicals was put in place in the event that any difficulty arose with the supply system upgrade. Procurement management was a vital function as numerous contractors were used. As part of the risk mitigation plan, outside contractors were required to apply project management processes to their scope of work.

 A complete startup, debug and production certification plan was developed and guided the project through this critical phase of the project.

•  Results / Outcome:

With the close cooperation of the client’s facilities, purchasing and production teams, each of the three systems were converted and certified production ready before the start of scheduled production after each shutdown period. All systems were ready for full production ramp-up at shutdown completion requiring only that the operators become familiar with the operating nuances of the new chemistry. There was no rework or repair required to any of the systems as originally installed during the shutdown periods.