All production facilities have one thing in common: they strive to maximize revenues and minimize expenses. Regardless of the industry, maximizing a plant’s yield and efficiency is something that should receive constant attention. Understanding certain things such as a facility’s energy and labor use can help you decide which decisions and procedures to utilize. The goal should be minimizing waste and producing as much final product as possible.
If your goal is to improve your bottom line, plant optimization is a key component of good operational management. The decision to pay strict attention to detail, controls, measurements and efficiencies not only improves the plant’s operation, but often produces much safer working conditions for the professionals on-site.
Improving Plant Operations
First, monitoring production for any deficiencies in performance and product flow are key. Faulty or damaged equipment can hurt your bottom line and more importantly, your staff. If you don’t measure something, you can’t control it. General and precise measurement of material flow and process parameters are important. Some of these measurements include the flow rate, temperature and pressure. Process specific measurements can include: product quality, reacting efficiency, inventory levels and so on. Daily measuring of inventory levels can be useful in tracking a plant’s long-term efficiency and material flow. Knowing the daily, weekly and monthly levels of material flow can shed light on whether or not a plant is performing optimally.
Repairs and Automation
Knowing what to look out for, as far as repairs and equipment related issues, can help protect your plant and your assets. In continuous processes, flow meters for liquids and weigh scales for solids continuously record the rate of material movement through a plant or facility. Whether you are measuring frac or cement, having a faulty scale or other piece of equipment can hurt business relationships and bank accounts. The goals of plant optimization are far-reaching:
Eliminate human error
Minimize process variation
Automated dosing of reagents into a reaction vessel
Checking all equipment
Auditing energy efficiency
There are many other questions to ask. Do waste streams have any amounts of salvageable finished product? Are thermal fluid heaters or other utilities operating within specified ranges? Are there more cost effective options for utility sources?
The TPS difference
We have a great deal of experience in plant optimization. TPS provides innovative solutions that can help protect your asset and save you money in the long-term. We do more with less while maintaining and improving quality and efficiency. We work to identify productivity lags, downtime and process optimization. Whether you need a complete plant overhaul or a number of repairs to key pieces of equipment, we have the necessary experience and knowledge to back up our claims. We make bold promises, backed by performance guarantees. After selecting the right project manager, we get your plant operational and profitable - faster than anyone else.