Development and optimization of processes in the company

Production processes simulation

Pre-start factory process simulations or optimization simulations of existing production / warehouse / transport solutions.

Example:
Checking process layout (including cycle times, number of the required workers, handling, etc.) and product flow prior to plant construction in order to optimize the process before work commencement.

• The action enables work reduction before the plant goes into operation .
• Moreover, the developed simulation will allow making adjustments on an ongoing basis before their actual application, which will save time and optimization costs (usually a lean team is appointed to perform this kind of verifications, which costs time and involvement of specialists from particular areas).

Organization of purchases

• searching for potential direct and indirect suppliers
• audit of potential and implementation support for suppliers
• consulting and training in purchasing
• creating purchase categories
  • MoB analyses (Make or Buy)
• identification of human resources
• securing the supply chain (including developing and securing deliveries of materials for production)
• purchasing processes outsourcing
• implementation or support in the implementation of strategies, processes and procedures

Implementation and improvement of management systems

• consulting and training
• training and implementation for ISO 9001 / IATF 16949 / ISO 14001 / ISO 45001 certification
• determination of human resources
• implementation or support in the implementation of strategies, processes and procedures

ERP/CAD/CAM/PLM systems

• assistance in the selection and implementation of optimal solutions

Production planning

• layout
• verification of needs for machines, equipment and processes
• implementation in accordance with Lean method
• training and consulting
• identification of human resources
• analysis of the selection of automatic and manual processes
• implementation or support in the implementation of strategies, processes and procedures

Organization of the supply chain (logistics and warehouses)

• choice of appropriate solutions
• layout
• identification of human resources
• analysis of the process automation
• training and consulting
• processes verification
• implementation or support in the implementation of strategies, processes and procedures
• choice of transport companies
• securing the chain of supply (including developing and securing deliveries of materials for production )

Total Productive Maintenance (TPM)

Selection of solutions

Choice and verification of companies and/or employees responsible for maintenance (production lines, installations, tool shop, choice of solutions)

Preventive maintenance

Ongoing evaluation of the technical condition of the machines in order to detect, locate and identify potential machine damage which may result in future breakdown.
The main advantages of this method include: reduction of costs incurred on account of machine maintenance, possibility of determining the optimal time for the realization of service works, repairs or replacement of the consumables indicated by the manufacturer.

Predictive maintenance

• Predicting failures of devices and production lines
• Detection of anomalies and problems
• Collecting data on the condition of infrastructure
• Ensuring full visibility and transparency processes
• real-time diagnostics and 24/7 monitoring of critical resources for the production line

Benefits of predictive maintenance

• Reducing the number of unplanned downtime and planning technical shutdowns
• Adjusting the stock of spare parts to the actual needs
• Collecting information on production efficiency and infrastructure efficiency
• Queuing of tasks and better planning
• Easier production analytics and determination of performance indicators
• Better supply chain management

Analysis and verification of manufacturing technology

• verification whether the adopted technological and process solutions are optimal and properly matched to the customer’s needs
• looking for alternative technological solutions in terms of cost and quality

Energy audits

Energy quality audit

Disruptions and failures of the power network cause large losses and downtime for enterprises. Their occurrence depends on the quality of electricity and other factors related to the power supply.

With experience and technical knowledge in the field of energy and the latest standards, we examine networks and energy quality
in industrial plants and public facilities. We assess the quality of power supply by measuring network parameters with the use of specialized analyzers, recording both basic quantities, voltages and currents, as well as indicators informing about the level of disturbances originating from higher
harmonics and other factors.

Measurements are carried out using portable devices that are equipped with a number of measuring probes, thanks to which the device can be connected to the switchboard. Installation of the analyzer does not interrupt the plant’s operation. After installation and programming, the device does not require any service, remains with the customer for the duration of the measurements, records and transmits data via a GSM modem. On their basis, an analysis is developed that shows irregularities and parameters relevant to the objectives of the measurements.

Improving Energy Efficiency

• Reactive power compensation
• Industrial lighting
• Improvement of the quality of electric energy
• Thermal energy management
• Compressed air management
• Energy management system and utilities monitoring

Energy Efficiency Audit

It is a specialist study that contains precisely described possibilities of increasing energy efficiency in the tested facility in terms of electricity, heat and cold management. Energy efficiency audits, created by certified auditors, contain a precise analysis of the energy consumed, and determine the technical condition of the facility, device or installation that has been tested. Such reports allow you to bring significant savings, lower production costs and greater competitiveness of the company.

An energy efficiency audit may be used to obtain financing for projects aimed at improving energy efficiency, e.g. in the form of energy efficiency certificates.

An energy efficiency audit is an analysis of the effectiveness of implemented or planned modernizations, completed with the preparation of a document in the form of a report. The result of the audit is the determination of the annual final energy savings [kWh / year] as a result of the project implementation.

Lighting audit

A professionally conducted audit should include, first of all, a reliable assessment of the current state of the lighting installation, as well as indicate possible solutions enabling the
modernization of the system with a precisely defined scope, technical parameters, etc. Our certified auditors make every effort to ensure that each such report also includes a precise
analysis of energy demand for lighting cells for individual rooms, including process lines. The test may concern both indoor and outdoor lighting (e.g. street lighting).

Compressed air audit

The scope of the performed audit includes:

• overview of compressed air applications,
• checking all leaks,
• inspection of devices intended for blowing, as well as collectors, nozzles and pneumatic transmission systems,
• verification of unnecessary and irregular receipts,
• measurement of pressure and compressed air flow in the main points of the company’s network,
• assessment of the transmission system and its capacity,
• overview of the most frequently diagnosed problems of compressed air use in the company,
• list of devices necessary for modernization in order to increase the efficiency of the existing system,
• proposed solutions that will increase the efficiency of compressed air installations (sealing of the installation, new configuration, implementation of energy-saving devices, etc.).

Audit of production technology

It is an assessment of the current state of the company’s technological potential, including the used procedures, implemented modern solutions and the machine park. It is worth emphasizing that this type of report is very often used to present specific solutions aimed at indicating the direction of the company’s development in terms of acquiring and implementing new technologies.

Audit of production technology can be carried out in order

• improving the efficiency and quality of production processes,
• to meet new, generally more economical methods of production,
• increasing the profits obtained,
• increasing the company’s competitiveness and strengthening its position on the market,
• receiving an independent assessment for the needs of possible business partners.

Audit of heat nodes

This service aims to develop a professional technical report on the heat source and related installations. The test allows for a detailed diagnosis of any irregularities, as well as for obtaining an expert assessment of the possibility of increasing the efficiency of the heat node.

The scope of our services includes:

• assessment of the technical condition with parameters of the node operation,
• providing recommendations for improving the operation of devices and parameter settings,
• ongoing maintenance of technological and power equipment, as well as the control and measurement equipment included in the node,

Certified specialists will check the heat substation in every respect, and the result of the activities will be a professional and substantive audit. In the prepared report, they will indicate, inter alia, the necessary modernization works and provide detailed information on the modernization of the node. In addition, they will provide expert advice on the costs of modernization, which can be covered based on EPC financing and White Certificates. A specialist audit of the substation is the only proven way to avoid incorrectly calculated charges as well as expensive repairs. It is also a guarantee of obtaining optimal parameters that will translate into even distribution of heat in the room.

Enterprise energy audit

Pursuant to Energy Efficiency Act of May 20, 2016 each large enterprise operating in Poland shall be obliged to perform an energy audit and to submit the report to the President of the Office for Energy Regulation within 30 days from its performance. Energy report shall be drawn up every 4 years. This requirement results from Directive 2012/27/UE of the European Parliament and of the Council of October 25, 2012 on energy efficiency.

Analysis and optimisation of production and/or management processes

Visualisations (2D and 3D) and simulations of production processes

Optimisations and improvements

• Identification and prioritisation of improvement projects
• Validation of proposed implementations within time constraints
• Analysis and recommendations for future state planning
• Facility layout and redesign
• Real-time process visibility
• Supply chain, storage and distribution optimisation

Benefits of simulation

• Production optimisation
• Identification and reduction of bottlenecks and constraints
• Forecasting, optimisation of schedules
• Optimisation of work allocation
• Productivity analysis and growth forecasting
• LEAN Six Sigma implementation
• Facility layout and design
• WIP inventory management and reduction
• Capacity planning and scheduling
• Other areas that can be supported

Assistance in model building, system analysis and optimisation. Helping you build accurate and effective simulation models quickly and cost-effectively. Whether you’re looking for a one-off simulation project, a team of experts to work with you on a solution, need a quick model revision or to use a new model as part of your training programme.

Optimisations and improvements

Procurement/Purchasing

• Selection of potential direct and indirect suppliers
• Support in CAPEX and OPEX investments
• Capacity audit and support in the implementation of suppliers
• Purchasing consultancy and training
• Purchase category building
• MoB (Make or Buy) analysis
• Identification of staff and team needs
• Outsourcing of purchasing
• Implementation or support in implementing strategies, processes and procedures

Quality

• Consultancy
• Training
• Preparation and implementation for ISO 9001 / IATF / ISO 14001 / ISO 45001 certification
• Identification of staff and team needs
• Implementation or support in implementing strategies, processes and procedures
• Analysis of the requirements of harmonised standards
• Compliance with legal and regulatory requirements
• Implementation or support in the implementation of strategies, processes and procedures

SCM

• Selection of appropriate solutions
• identification of human resources
• Process automation analysis
• Consultancy and training
• verification of processes
• Selection of transport companies
• Implementation or support in implementing strategies, processes and procedures

Lean Manufacturing

• System planning
• Verification of machine, equipment and process needs
• Implementation procedure according to the Lean method
• Consultancy and training
• Identification of staff and team needs
• Analysis of the selection of automatic and manual processes
• Production
• Implementation or support in implementing strategies, processes and procedures

Other areas that can be supported

• Project management
• Engineering
• Reverse engineering
• System solutions
• ERP/CAD/CAM/PLM/SCADA/MES

Production of components and production and control instrumentation using 3D printing technology

Modernisation, improvement, repair, expansion of machinery and control and instrumentation equipment using 3D printing and 3D scanning technology. Production of components – industrial 3D printing.