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Sitting in a traffic jam can be frustrating and is rarely a productive use of time. Likewise, the delay caused by waiting for Common Systems can erode the productivity of a step in a sequence operation, the completion of a batch, and eventually total plant operations. Whether the overburdened Common System is a utility, raw material supply header, set of service equipment, or some other pinch point, rush hour can have a costly impact on efficiency. For instance, six reactors, spending an average of ten minutes waiting on a Common System while completing a batch turns into a full hour of lost production. Significant production is lost when this cycle is repeated through thousands of batches a year.
Build Another Road?
Just as the cost of new roads can't always be justified, adding costly new equipment, especially if the Common System causing the traffic jam is otherwise adequately available, may not make sense. In exploring value opportunities for our clients, we will often avoid the lost production by either avoiding the traffic jam altogether or by automating a response.
Avoid the Traffic Jam
Have you ever received that call from a friend, "don't take the interstate home today, it's all backed up!" Just like that call, your plant's automation systems can warn you when a backup is coming and take steps to prevent the jam.
In the age of lean manufacturing, production order is set by frequently changing demand. But nor should the plant be run inefficiently. By using state of the art tools, we can help you automate the response by:
Taking these steps to avoid or eliminate the cause of unnecessary downtime can have a significant impact on your bottom line.