FRONT
END LOADING - The Right Way
There
are numerous definitions of, so called, "Front End
Loading"(FEL). The
way I prefer to describe it would be............. "Those THOUGHTS,
PLANS, PROGRAMS AND ACTIONS that will identify WHAT we want,
BEFORE trying to achieve it"!
"Look Before You Leap" is putting it another way.
I submit that It would be irresponsible........ and
intellectually negligent not to use the FEL concept in any of our professional
efforts. There are all
sorts of benefits to paying attention to this principle and many of us
don't need persuasion. On
the other hand, I feel that we sometimes
pay "lip service" to FEL, particularly at the intermediate to
high management levels in the DuPont Company.
And sometimes the "workers in the trenches" don't have
time to think first...........so they use
traditional approaches.
The
point of this note is to share some thoughts around what I think is
"The Right Way" to initiate and conduct a FEL program
that potentially can lead to a Capital Project.
This, and certain STRATEGIC COMPUTER APPLICATIONS show the way to
Miller's and Todd's (Engineering Managers at the time) VISION of 25%
less project investment, 25% less time to install facilities and 25%
less manufacturing operating cost.
Here
are ten ideas that might guide Front End Loading in The Right Way,
and contribute to QUALITY Project Basic Data.
AND perhaps, the production design force in PED (The Project
Engineering Division) will then "Know It When They See It"!
1. COMPLETE Project Basic Data is composed of:
* PROJECT OBJECTIVES
* RESEARCH DATA
* PROCESS FLOW SHEETS
* PRELIMINARY FUNCTIONAL DESCRIPTIONS
* MANUFACTURING SITE DATA
2.
Flow Sheet DEVELOPMENT is required in PARALLEL with
the collection and preparation of the Research Data.
This will permit INTERACTIVE flow of information between those
developing the process systems and those obtaining laboratory
and pilot plant data.
3.
The completion of Project Basic Data, including the FINISHED FLOW
SHEETS, PRIOR to PED P&E activity will significantly contribute to
the achievement of a STEP REDUCTION in E&HO (Engineering & Home
Office Expense) cost and reduced time for CAC (Current Appraisal of Cost
- for initial authorization) - preparation.
4.
Quality Project Basic Data must include the contributions of
RESEARCH, MANUFACTURING, ENGINEERING and PRODUCT DIVISION
people. The ideal team composition to handle the responsibilities
in item #1 above would be:
+ Marketing Engineer...Business Center/Product Division
+ Research Engineer....R&D Division
+ Project Engineer.....Project Engineering Division (PED)
+
Process Engineer.....Plant Technical Group (Mfg Div)
+ Site Engineer........Plant Engineering Group (Mfg Div)
5.
DIRECT LINKAGE between the process simulator (Aspen or Process)
and the flow sheet preparation device (Intergraph) will permit rapid
intercommunications during process development.
This is something that we do not have now, but NEED!
6.
It is PRUDENT to RISK the expense of an ADEQUATE FEL PROGRAM
rather than sink back into the traditional doldrums of "start
and stop" production design and the associated lost P&E
(Plans & Estimates - 1st authorization to start conceptual design)
money to cost.
7.
The Basic Data Development Team, as specified above, must be
dedicated to the task of collecting the Basic Data and FREE
FROM DISTRACTION and other responsibilities to produce a STEP
CHANGE in PERFORMANCE.
Relocation may be required.
8.
The most efficient way to proceed with Conceptual, and then
Final design is to reassign the development team members to NEW PROJECT ROLLS after the Front End Loading period.
However, having a QUALITY Basis
For Design in-hand, new project people
can be brought "up-to-speed" more quickly than before. Also note that FEL
principles can and should be used throughout the project!
9.
The Basic Data Development TEAM members should be TECHNICALLY ORIENTED
in addition to having business and administrative perspective.
The PED member should be capable of configuring the process, operating the simulator and preparing graphic,
well thought-out FLOW SHEETS that summarize the BASIS FOR DESIGN.
The Plant Technical engineer will need to visualize the
individual process steps and postulate a FUNCTIONAL DESCRIPTION.
The marketing engineer will be
the link with business reality and
be the interpreter, if not the writer of the PROJECT
OBJECTIVES...........that include what DuPont customers really
need in terms of PRODUCT SPECIFICATIONS.
The Research Engineer must
have expertise in the particular technology and the ability to produce the RESEARCH DATA resulting from laboratory and pilot
plant programs. The Site
Engineer will bring the local plant
situation into focus as it relates to the newly postulated
facilities and be responsible to provide the MANUFACTURING
SITE DATA. All Team members will have to be able to "fill in the
holes" during the development of the Basic Data.
Obviously, MANAGEMENT will
have to use MAXIMUM SKILL AND CARE in selecting this group.
10.
Industrial and Engineering Department MANAGEMENT COMMITMENT to
FEL is absolutely vital. A
lot could be said about this area, but
if we can somehow convert the above management VISION into a believable
and communicable "meme", AND let this team and their resources
be truly CREATIVE and INNOVATIVE, the Step Change will happen!
F.
L. Arbogast - November 23, 1988 - Newark, Delaware |