Ultramax (UMAX) 7.2 Optimization Study (Stand-Alone license): Standard Implementation Plan

Advanced Process Management 1990-2011 Ultramax Corporation (UMC), Cincinnati, Ohio, USA. All rights reserved. ImplementationPlan.docx 12/12/10

Step Description

Time involved in a formal change of Operating Procedures of a somewhat complex manufacturing process (~15 inputs, 20 outputs), times dependent on process and team size economies of scale for more than one concurrent optimization study. The two left columns and steps in red indicate the Supplier and Client time of the first application; and the Regular, Self, Client time after being trained and self-sufficient. While planning, documentation and commissioning times are similar to DOE or NN projects, the great savings in time are in training, interaction with production and in the analyses.

Supplier time

(man days)

Client time

(man days)

Calendar time

First application w/ full Services

days

weeks

First application

w/ full Services

Regular, Self

 

1

2

3

4

5

6

Pre-work

 

 

 

 

 

 

 

 

 

 

Questionnaire: Preliminary evaluation of Scope, discussion (free service before contract)

0.5

1 hr

1 hr

2

 

 

 

 

 

 

Client initial self-training, per person (any number possible); typically after contract is signed.

 

1

 

1

 

 

 

 

 

 

Project: Training review, Planning, Setup, Documentation

3

5

3

4

 

 

 

 

 

 

Introduction: Present UMAX, understand management situation and needs. Visit process operations; review Questionnaire facts, data gathering. Training Q&A review.

1

(on-site)

1

 

1

 

 

 

 

 

 

Formulate Optimization Plan (and training) about four-people team (2 hrs. management participation)

1

(on-site)

4

2

1

 

 

 

 

 

 

Write Optimization Plan report, management approval. Setup Ultramax file and data collection spreadsheet.

1

0

1

2

 

 

 

 

 

 

Start Production Operations with Sequential Empirical Optimization (SEO) cycles

6

4

3

9

 

 

 

 

 

 

Collect operating data using current operating procedures to establish a data collection method, and to have reference data for about 10 runs to calculate future improvements. Done before visit by optimization expert.

 

1

1

3

 

 

 

 

 

 

Continue production operations with adjustments modulated by Ultramax, with on-site Supplier guidance, usually one week. On-the job production team training. Commission Ultramax to the client at end.

5

(on-site)

3

2

5

 

 

 

 

 

 

Write Commissioning Report, presentation to management.

1

0

 

1

 

 

 

 

 

 

Client capable to continue on its own, with remote support

TOTAL K$

9

11

6

13

 

 

 

 

 

 

Client Completion of first Optimization Study

5

3

4

12

 

 

 

 

 

 

Client continues production operation with Ultramax until Final Report, with periodic technical analyses. Remote support. Assume two more weeks, but depends. Usually operators collect and enter the data.

2

3

3

10

 

 

 

 

 

 

Technical Review, write Final Report, presentation to management

(Each additional Quarterly Review (visit, analysis, report, presentation to mgmt. takes about 3 days/ appl.

3

(on-site)

0

1

2

 

 

 

 

 

Project Completion; client trained and capable to make new Studies on its own
(continuing remote support programs available)

TOTAL K$

14

14

10

25

 

 

 

 

 

 

Option, add Integration: Automatic data exchange with Process Control System; to implement on-going, on-line dynamic optimization (as conditions change), installed after Planning or after completion of the Study. Highly dependent on existing process control system. Includes two more reviews.

+20

+15

+5

+15