Prevent production downtime or backlogs by properly securing and maintaining your installations and infrastructure, and ensuring that staff are appropriately coached.
An obsolete ammonia refrigeration system with a total capacity of 2,400kW, in the city centre. As soon as possible, replace the system, which is in an operational distribution centre, with no CAPEX investment. How do you do that? Delivery times are currently rapidly increasing and such installations require a substantial investment. Although the solution is simple, it was not obvious: ‘rental’. By renting a new refrigeration system, all relevant installations could be replaced at very short notice and no CAPEX investment would be required. We take care of the entire process, from engineering to project management, including supervision during the project. The foregoing had to take place in an operational distribution centre, avoiding downtime.
“Replace the entire warehouse automation system at our distribution centre. Turnkey delivery, on time and on budget . From PLC to warehouse management and ERP system. Completely cybersecure, avoiding production downtime.” This project commenced a year and a half ago and was a resounding success! Two hundred and 60 (inbound) and 280 (outbound) pallets per hour are processed, stored or loaded as part of a fully automated system. For this project, we provided programme management, analyses and calculations, engineering and procurement. We supplied scanners, terminals, printers and labels. All systems were tested individually and in real time at weekends (including EWM/MFS -SAP-, MES interfacing, Siemens TIA, LJU shuttle system, OT hosting and IT hosting in redundancy across 2 MER rooms). We brought together all disciplines, made sure everyone was involved and we ensured that the relevant staff could operate and maintain the system. The new automation was enthusiastically received and taken into use across the entire organisation.
After more than 20 years of faithful service, it is time to replace the cooling water chillers at Centrient in Delft. But how do you do that when you must maintain full capacity and when the investment is huge? The authorities are breathing down your neck. New solutions must be sustainable and making sacrifices in terms of processes is not an option.
Dilemmas of this kind can sometimes result in a deadlock; you cannot afford this because of the lead time. You can only resolve this by working intensively with all stakeholders, engineers and suppliers.
We looked for a supplier with a sufficient level of knowledge, who understands the situation and could help shape the business case. We calculated ways in which replacement could also be financially beneficial and visualised the process. We could then get down to business.
Over a period of four years, the entire refrigeration system will be replaced. Replacing the chillers in the autumn and spring minimises the impact on the production process. The outside temperatures then work in our favour. Production safeguarded. Environment safeguarded. Client happy. Local authorities happy.
Build a new factory, installation or production line within all set deadlines that is fully aligned with all relevant departments and processes. If an installation has to be integrated into an existing process, we keep downtime to an absolute minimum.
“Develop a completely new production line for ice cream and milkshakes at our Cologne plant, in keeping with the processes at our Lummen plant.” The reasons for this were twofold: currently the demand is greater than capacity in Lummen and FrieslandCampina wants to be able to supply the Quick Service Restaurant market quickly from Germany ('Made in Germany'), but experience shows that processes, systems and installations can rarely be copied one-to-one from one plant to another, which applied here too. We found the correct place in the factory to develop the line, we aligned all processes and provided EPCM for the entire (brownfield) process, enabling the line to be put into operation within 1.5 years of the award of contract.
Gain an understanding of the performance of your installations, processes and factory. Be aware of what’s happening and track developments and trends. Make informed decisions using the right tools. We can perform a business scan, provide comprehensive analyses or implement a complete MES system.
In a factory, everything is interconnected. A change in one process often has a direct impact on other processes and departments. You can, of course, use this to your advantage. When tasked to replace the existing data collection system, we placed this within the wider context of the OT Master Plan.
A relatively simple modification to the system would enable us to take major steps towards a higher OT level. This was achieved within virtually the same time frame, with minimum additional effort and without significant investment. In parallel to the implementation of 'Aveva Historian', we implemented a new hosting platform and contributed ideas about the effective use of collected data. That starts with deciding how you wish to utilise your data and, based on that, defining key figures, structures and queries. The value of this preliminary work was evident in an initial Proof of Concept, which provided data on the evaporator that could be interpreted and utilised immediately. A solid foundation of this type enables you to extend your success to other lines and departments quite easily and in a standardised way.
Utilise the full and maximum capacity of your equipment every day and make the best use of the talents within your team. Experience how to achieve the best possible results every day, in quality and in quantity.
“Ensure that our new ‘Electrical systems and Instrumentation’ meet all EHEDG guidelines and other prevailing standards, and can be commissioned this year.” When we join the project, assembly is at a standstill and an immediate solution is needed. A hygiene upgrade is also underway in the relevant departments. Whilst the formal award of contract process was being worked on in the background, we conducted a comprehensive survey. We then immediately drafted installation guidelines, involved existing installers in the process and fine-tuned quote requests to put into effect a new and effective network platform. By also taking responsibility for the E&I, we were able to change course quickly, with zero loss of lead time (downtime?) and the entire installation will be commissioned (within budget) in June.
FrieslandCampina Veghel is one of the largest lactose plants in the world. In order to guarantee maximum output 24/7 and to continue to meet the highest (quality) standards, a decision was made to replace the lactose transport system. All the lactose powder produced is transported from the production building to the packaging plant via a 140-metre-long and virtually maintenance-free pipe system. From there, the powder is packaged into various packaging units. Because lactose is quite sticky, when it is transported in long process pipelines, there is always a real risk that they will become clogged. Thanks to high-tech engineering and extensive testing, we were able to design a transport system that ensures that the pipelines do not become clogged. During the project, production could not be suspended for long, if at all. A 'brownfield' approach and delivery in a factory where every square metre was already being utilised. Nevertheless, the project was successful: both the process and the commissioning went smoothly.