Production Optimization

Understanding Overall Equipment Effectiveness (OEE) is crucial to maximizing production and identifying process bottlenecks. While measuring OEE is the first step, customers need to know how to improve it. Our team of experts helps clients accurately measure OEE, identify improvement opportunities, and develop solutions to increase efficiency and margins.

Real-time scheduling on the manufacturing floor requires defined rules and a proven software solution. We need to accommodate variability, maximize production, and consider information from multiple sources (ERP, QMS, MES, DCS, LIMS, and CMMS). Our integrated solution allows for efficient production scheduling with simulation planning for various scenarios, while ensuring smooth coordination between departments.

Proper batch design requires understanding each unit’s operation, visualizing the end goal, and incorporating flexibility, while avoiding recipe complexity. We can reduce cycle time by over 30% by listening to production, applying solid batch strategies, thorough testing, and then training end-users. Our architecture is based on industry standards and a class-based configuration for procedural models.

Our state-based control solution combines operator-initiated transitions and automated control logic to drive a process to its desired state. Communication among units keeps the process aware of ready states, temperatures, pressures, and other process variables, ensuring each step happens only when the system is ready. Features include automatic startup, shutdown, and abnormal situation management to reduce operator interventions.

Advanced Process Control (APC) technologies leverage machine learning and AI to optimize and adapt control systems in dynamic processes. Collaboration between production and automation teams ensures successful deployment. We can develop and deploy APC solutions that lead to improvements in throughput, energy consumption, and product quality deviation.

A Digital Twin is a virtual model of the control system and plant production environment used to simulate the process, test process changes, and provide operator training. We have the expertise to implement the appropriate Digital Twin to improve process performance, safeguard operations, and deliver a safer and more cost-effective operation.

Operators need to focus on critical alarms to avoid costly distractions. Our tools allow you to assess alarm performance and guide your through a rationalization process to help manage alarms more effectively and create an environment where operators can work efficiently.

Control room design plays a crucial role in plant operation and safety, but outdated designs may not suit modern technologies. Our approach involves task analysis, ergonomics, stakeholder engagement, security, break areas, storage needs, and collaboration. Once aligned on a design, we have the resources to fully engage in the detailed design, and ultimately manage and execute a retrofit project.