Converging Paths
In this section we will mention and discuss some, hopefully most, of the processes involved in an industrial project.
What we think is important to take away is that the owner, someone on the owner's staff, or perhaps the project manager should make a sincere effort to discover all the processes and obstacles that will be encountered. Then, using one of the commercially available project management software programs, such as Microsoft Project, prepare a file that describes each process as a network of tasks with appropriate time durations assigned.
Next a master plan can be made by importing the individual processes and linking their milestones into one coherent project plan/schedule. The process at this point is very similar to the classical process. In the next step, one very key element is that the schedule is constrained such that the end point is the date needed by the business and no other value.
On the first pass it is common to have a schedule that is too long and a critical path that is too long. Use this first pass schedule to see what processes can be done concurrently, or early, to shorten the critical path acceptably. It may take several passes to find the best preliminary plan/schedule for your work. The end date, the date required by the business can never be compromised.
The more common processes we have encountered are:
- Product and market development
- Laboratory. It must be proven that the product can be made repeatedly, and passes a quality criteria repeatedly. This step is not required if technology is licensed.
- Pilot plant. It must be shown that quality product can be made safely in an industrial method and enough product must be made to distribute trial lots for market testing. It may be possible, for a licensed product, that market testing be done using product made in the "mother" factory.
- Low rate initial production. It may make sense to expand the pilot plant to serve the initial market while a main production facility is built. Again, for a licensed product it may be possible to serve the market from the license supplier during this period.
- Full production. After erection, start-up and debugging, the market can be served from the new facility.
- We will mention at this time that if product is to be made initially at another location and later manufactured at another, one will be required to "synchronize" quality testing to ensure that product locally produced and product from the original supplier are identical in every way. We have never experienced a smooth synchronization and recommend this task be accomplished sooner rather than later.
- Archeological and Historical Survey Report
- Land Use
- Comprehensive plan. A periodically renewed state-wide growth/zoning plan. Changes are possible but complex. If you need changes to this plan, we recommend you seek help from an attorney that works in this area.
- State, county, and local building codes. These can contain restrictions on construction close to water, environmentally sensitive areas, parks, or designated area. These codes are on file and need to be reviewed (or skimmed at least) to see if restrictions exist that could affect your intended project timing or costs.
- Concurrency plan. This is the overall plan the state, county, and local governments are following to fund and maintain adequate infrastructure.
- The local construction permitting process
- Community
- Environmental
- CAAA Air Construction Permit and Air Operating Permit
- NPDES Construction Permit and Operating Permit
- Wetland Impact
- Class 1 areas and Pristine Waterways
- Sites possibly contaminated previously
- Superfund Sites
- Flora and fauna survey for protected species
- Preliminary Design
- Project scope. A document describing products to be made (rate and quality) is prepared. If any opportunities for early revenue exist, they should be identified here also.
- Preliminary plant layout.
- Material balance
- Process Flow Diagram
- Interlocking diagram
- Equipment list
- Specifications for major or long lead items of equipment
- Funding
- Detailed design
- Construction
- Start-up
- Safety
New products or processes generally come from one of three sources, accidental discovery perhaps by a researcher, planned discovery by a team given the task of inventing the product, manufacture under license from another supplier. Regardless of source the product introduction usually involves four stages although how long it takes to mature each stage can vary greatly depending on the technology source.
This may be a location required survey. Even if it is not required we recommend that it be done. If evidence of previous construction is unearthed during the project, the job will stop until it is determined if the previous construction is of archeological or historical value or not. In this case a survey on file can prevent a project delay.
Some years ago development was not well controlled. for example, housing developers would build a subdivision, sell houses, and move on leaving a city or county with areas of under developed schools, roads, water supply or sewerage. A lot of legislative work has been put into place to ensure that development is encouraged but controlled to a point that services can keep up growth. Some of the methods imposed by legislators are:
Very early in the process a proactive plan needs to be developed to assure community acceptance of the project. The days of people accepting any industrial project because it meant jobs are long gone. A major concern today (right or wrong) is effect of a project on local property value and quality of life. There is also an element of interfering for sport. It can be countered. We don't undertake community acceptance, but we have seen some very effective programs in action and some unexpected failures when the community was underestimated.. Interested parties can email us for a discussion of the topic.
This is the work executed to define a project well enough to make a valid estimate and obtain funding. We work her as both engineers and as managers. the major steps usually are:
Every business has its method for obtaining project funds.
We'll discuss this in detail in the next section.
We'll discuss this in detail in the next section also.
We have discussed this in detail in the chemical engineering section.
The required reviews have been prescribed by OSHA and we defer to their judgment not to mention their authority. The requirements do change as refinements are made. Do review the latest requirement and ensure they are incorporated in your plans.
Not every item mentioned applies to every project but a thorough review is needed to prevent any costly surprises. Every industrial project is constrained by the need to be on time to market with the product at the forecast cost.
In the next section we will discuss how we like to see work managed at an Architect-Engineeing firm and during construction. We think the method is very effective.