1. Project Phase 1
Value stream mapping of Pilot plant
by
Schawan Kunupakaphun
Srividya Sharvankumar
Rushi Patel
2. Content
What is Pilot Plant?
Process Flow for Pilot Plant
External and Internal customer Requirements
Work time
Process information
Value Stream Mapping
Area of improvement
3. Pilot Plant Trial for a New Product
● Pilot plant runs trial for various compound that are developed in an R&D
● The compound is tested for the feasibility of its commercial production
● Provides sample of the product to the expected customers for them to test
the product in their facility.
● On time delivery of samples to the customer is critical. As the sample will let
the customer to provide us the commercial scale production order if the
material passes their specifications.
● pilot plant aims at testing the process within the existing facility available at
the pilot plant
● The value stream for the pilot run in this project is related to a single product
4. Process Flow for Pilot Trial
● Upon the arrival of the order for a sample production following are the series of
event followed:
● Decide the operation philosophy for the process.
● Execute the modifications.
● Checking of the changes
● Information to operating team
● Conduct the run
● Data compilation
● Product packaging
● Discussion on findings of batch with the design team
● Dispatch of material to customer
● Two suppliers involved:- Process chemical supplier( supplier 1) and Starting Mat.
supplier(Supplier 2)
● Lead time for obtaining both material is two weeks by 2 shipment every week.
5. External Customer Requirements
● 50kg of pyrazole acid per month
● Specification for the final product is provided to the production control team.
● Customer order to produce 150 kg within 3 months.
● 3kg material in PTFE cans
● Weekly shipment
● Pharmaceutical company requires orders to come 30 days before shipment.
Internal Customer Requirements
● Weekly updates regarding the product dispatch
● Weekly progress from the production team about the new findings and issues in
the operation.
● Weekly process data collected in all the operations during all the shifts.
6. Work Time
● 330 days per year
● Three shifts in all production department.
● 8.5 hrs every shift with 30 mins break during each shift.
● Manual process stops during breaks.
● 30mins of lapover time between each shift.
7. Process Information - Reaction
● Batch process with 2 operators per shift.
● Number of shifts: 3
● Cycle time : 8hrs
● Changeover Time : 4hrs
● Changeover Frequency : 2 per day
● Observed Inventory:
o 10 days of unreacted raw materials
o 1 day of reacted material.
● Uptime: 67%
● Yield : 100%
8. Process Information - Filtration
● Batch process with 1 operators per shift.
● Number of Shifts: 3
● Cycle time : 10hrs
● Changeover Time : 3hrs
● Changeover Frequency : 2 per day
● Observed Inventory:
o 4 days of filtered material.
● Uptime: 83%
● Yield : 90%
9. Process Information - Distillation
● Batch process with 2 operators per shift.
● Number of shifts : 3
● Cycle time : 12hrs
● Changeover Time : 12hrs
● Changeover Frequency : 1 per day
● Observed Inventory:
o 1 day of final product
● Uptime: 50%
● Yield : 98%
10. Process Information - Packaging
● Manual process with 1 operators per shift.
● Number of Shifts: 1
● Cycle time : 3hrs
● Changeover Time : 1hr
● Changeover Frequency : 2 per day
● Observed Inventory:
o 7 days of packed product
● Uptime: 75%
11. Value Stream Mapping
Pilot plant
Customer 2
Engineering Design
30 days2 weeks
Supplier 2
(Catalyst and
starting materials)
Supplier 1
(Process Chemicals)
Receiving
I
10 days
Production
Control
1 day
C/T = 8 hr
C/O = 4 hr
CoF = 2/day
Upt = 67%
Yield = 100%
Shift = 3
Reaction
(O) 2
I
1days
C/T = 10 hr
C/O = 3 hr
CoF = 2/day
Upt = 83%
Yield = 90%
Shift = 3
Filtration
(O) 1
I
10hrs
I
1 day
C/T = 3hr
C/O = 1 hr
Upt = 75%
Shift = 1
Packaging
(O) 1
2* week
Production Supervisor
Weekly
12hrs 3hrs
8hrs
10 days 1 days 4 days 1 days 7 days
Total LT = 23days
Total VA time = 33hrs
Weekly
updates
Engineering
design
1 day
Modification
7 days
50 Kg/mo
PTFE Can = 3kg
Product Dispatch
I
7 days4 days
Weekly Progress
Customer 1
Daily Schedule
Checking Modification
2 days
C/T = 12 hr
C/O = 12 hr
CoF = 1/day
Upt = 50%
Yield = 98%
Shift = 3
Distillation
(O) 2
12. Takt Time
Total available working hours in a month = 27.5 * 24
= 660 hrs
Total Quantity to be produced per month = 50 kg
Takt Time = Time Available/ Qty Required
= 660/50 = 13.2 hrs/kg
Overall Cycle time => 33hrs to produce 3 kg
= 11 hrs/ Kg
Hence the overall cycle time for the process < Takt time
13. (O) 2
C/T = 12 hr
C/O = 12 hr
CoF = 1/day
Upt = 50%
Yield = 98%
Shift = 3
Value Stream Mapping
Pilot plant
Customer 2
Engineering Design
30 days2 weeks
Supplier 2
(Catalyst and
starting materials)
Supplier 1
(Process Chemicals)
Receiving
I
10 days
Production
Control
1 day
C/T = 8 hr
C/O = 4 hr
CoF = 2/day
Upt = 67%
Yield = 100%
Shift = 3
Reaction
I
1days
C/T = 10 hr
C/O = 3 hr
CoF = 2/day
Upt = 83%
Yield = 90%
Shift = 3
Filtration
(O) 1
I
10hrs
I
1 day
C/T = 3hr
C/O = 1 hr
Upt = 75%
Shift = 1
Packaging
(O) 1
2* week
Production Supervisor
Weekly
12hrs 3hrs
8hrs
10 days 1 days 4 days 1 days 7 days
Total LT = 23days
Total VA time = 33hrs
Engineering
design
1 day
50 Kg/mo
PTFE Can = 3kg
Product Dispatch
I
7 days4 days
Customer 1
Daily Schedule
Checking Modification
2 days
Distillation
(O) 2
14. Area of improvement
● The raw material stays in the warehouse for 10 days before the process is
started which needs to be reduced.
● There is holdover for all the intermediate material with the intermediate after
filtration to be as high as 4 days.
● The finished product stays in the warehouse for 7 days before the customer
pulls it.
● Product stays in inventory for 7 days therefore no.of shift is high.
● Staffing for the reaction and distillation has high number of operator.
● The uptime is very low for the reaction and distillation steps.
● The changeover time is high for all the processes.
