Upgrades for Improved Efficiency
CASE STUDY
The creation of two standardized, operational drying machines capable of working together with shared resources and replicable for other facilities.
OBJECTIVE: The project’s objective was to have two safe, operational machines that met manufacturing standards, worked in unison with shared equipment, and could be replicated for use in other facilities.
CHALLENGE: Due to the machines’ substandard programming, neither machine worked as intended. Since the company intended to replicate the machines for use in other facilities, determining a method for standardization was important; however, these machines were transitioning from the R&D department to the production department, so the design had not yet been finalized.
In addition, proper protocols had to be followed to meet ultra-high purity standards.
Solution
Complete Turnkey Solution
After completing a FEED study, a turnkey solution was created that involved completing the design of the machines and rewriting the program to make it function as designed. It was a complicated program that required testing and vetting to ensure both machines worked in unison with shared equipment.
The solution included writing the control narrative and documentation, programming both machines to work using shared resources, completing the mechanical and electrical installation of the machines, testing their functionality to ensure alignment with the approved control narrative, and contracting electrical and mechanical workers to complete the construction of each machine. Through quality and safety checks, the mechanical contractor followed the proper protocols and produced quality welds, and the electrical contractor terminated, and loop checked complex instrumentation and control system components. All stakeholders worked hand in hand to ensure a quality installation.
To meet the ultra-high purity standards, creativity and adaptability were needed to source long lead time ultra-high purity stainless steel fittings that became necessary due to a changing scope as the project progressed at a fast pace.
Results
Improved Processes & Operations
Before the project, the supplier had an older version of the machine that could only dry two ampoules and involved a manual process. With the new machines, the company can put eight ampoules in the drying mode simultaneously and let them run. With the design finalized and standardized, the supplier has the means to replicate the machines to be used in other facilities. In addition, the automated process generates a higher throughput and allows operators to gain production in other areas of the facility.
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