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BPE’s confidential client wanted to assess the impact of an increasing number of products vs smaller production volumes. Existing process equipment was scaled for larger manufacturing volumes resulting in significant product wastage and inflexibility.
A new manufacturing concept was required but it was critical for this to be fully optimised in terms of both Capital and Operating Costs to meet the business case. The design required an appraisal of production volumes and the integration of a range of batch sizes into a flexible manufacturing model based on speed of product change and high yield operation.
BPE undertook a comprehensive design study that included analysis of production scheduling and material and personnel flows as well as equipment design/specifications, layouts and automation/controls philosophy. The selected options were costed both in terms of the required facility upgrades and also in terms of ongoing operations.
The design study was part of a wider review of investment planning across a number of operating sites. The BPE design report provided a key element of rigour to the decision-making process.