Process Performance Audit
Push the process to the optimum
Production processes require a lot of effort, knowledge and creativity to operate on well performance. Pushing the production processes above the industry average requires a vast amount of knowledge. We can help to make your process perform optimally.
We take on the risk of performance improvement by analysing your production process for free and if real potential for improvement exists implementation follows and achieved benefits are measured. You will know exactly what you are paying for and payment will be due only after the project has returned it's value.
Achieved by adjusting your control system only. Better control means that it is the control system adjusts the process, leaving the operation personnel to focus on directing the system. This frees up the operator's time so they can turn their focus to better operation of the process.
Push closer to optimum. Achieving optimal operation is not that easy, because the plant needs to be pushed to the point where it has never operated before. With the extensive data analytical and statistical tools we use it is possible to calculate new operation targets which give the process the same safety margin it had before.
Each benefit category is assessed and measured.
Specific tests are made to certify the achieved results.
Paid on delivered benefits
We are confident about delivering the results we promise so that payment can be based upon the quantified benefits.
How the benefits measured?
Achieved business benefits are measured after optimisation and compared to the performance before.
In order to measure benefits all process are characterized by viewing all inputs and outputs. Couple of months of operational data gives enough information to make highly-precise estimation of improvement. All processes are different or operated differently so benefit calculation algorithms are adapted for each individual processes in cooperation with you.
Typical business benefits delivered and assessed. Some benefit categories are industry and process specific. During the initial consultation process only the categories which deliver tangible business benefits are assessed.
Less specific energy consumption and decreased utility cost.
Stable quality with good repeatability.
Higher performance to operate at peak performance whenever needed.
Less chemical dosage.
The operators can turn their focus to the process rather than controlling it.
Decreased maintenance due to significantly decreased variance.
Less stress on process equipment which increases its lifetime.
Significantly reduced alarms.
Your process control system is the first level barrier to a safety risk.
Example - Increased Throughput
Prior to our process operation was only possible at a low rate due to equipment uncertainty. Process stabilization enabled increase of the feed rate and running of the operation with highest production throughput.
If you have special questions or are interested in details, we are here to listen and answer.
Typical data requirement
Data analysis usually requires the following data inputs. If you send us the design documentation we can prepare the data export sample file for you.
Custom non-disclosure agreement available on request.
Time series data
Process control system configuration
Piping and Instrumentation Diagram
Process Flow Diagram