PROCESS ENGINEERING

TRIAL

SERVICES

At Projectek, we understand the importance of conducting trials to validate processes, technologies, and new product developments. Our trial services are designed to support you throughout the trial process, from scoping out customer needs to delivering conclusive reports. We offer the following trial-related services:

Scoping Customer Needs for Trials

We work closely with you to understand your specific requirements and objectives for conducting trials. Our experienced team will collaborate with your stakeholders to gather essential information, define trial objectives, and outline key success criteria. By thoroughly scoping customer needs, we ensure that trials are aligned with your goals and expectations.

Trial Plan Development:​

Based on the scoping exercise, we develop comprehensive trial plans tailored to your unique project requirements. Our trial plans outline the methodology, test parameters, sampling procedures, and data collection techniques. We pay meticulous attention to detail, ensuring that trials are conducted with precision and accuracy.

On-Site Trial Execution

Our on-site trial execution involves deploying our experienced team to manage and oversee the trial process. We work closely with your staff, coordinating activities, collecting data, and monitoring trial progress. With our expertise in project management and hands-on support, we ensure that trials are conducted smoothly and in accordance with industry best practices.

Conclusive Trial Reports

After the completion of trials, we provide comprehensive and conclusive reports that summarise the trial outcomes and findings. Our reports include detailed analysis, statistical data, and actionable insights to support decision-making. We present the information in a clear and concise manner, allowing you to gain valuable insights and make informed decisions for future project developments.

At Projectek, we take pride in our expertise in process engineering—a vital aspect of our project management consultancy services. Process engineering lies at the heart of most of our projects, encompassing the design, optimisation, and management of industrial processes to achieve efficient and effective results.

We bring a wealth of knowledge and hands-on experience in designing and implementing various industrial processes. From project inception to successful commissioning, we remain dedicated to maintaining a constant focus on the process. By doing so, we ensure that the solutions we deliver are aligned with the original project targets or even surpass them, guaranteeing the realisation of predicted benefits and returns.

Our process engineering services cover a wide range of activities. We excel in process design, meticulously developing detailed plans and specifications for new processes or enhancements to existing ones. With an eye on continuous improvement, we continuously seek opportunities to optimise processes, minimise waste, and enhance overall productivity.

Safety and environmental considerations are at the forefront of our approach. We prioritise the implementation of robust process control systems, monitoring and regulating key parameters in real-time to ensure safe and compliant operations. Our team is adept at troubleshooting and problem-solving, addressing any issues that may arise during process operations, and implementing effective solutions.

Our commitment to sustainability and adherence to safety standards make us a trusted partner for clients across various industries. As we navigate the complexities of process engineering, we remain focused on delivering outcomes that align with your goals while adhering to the highest standards of quality and safety.

With Projectek’s process engineering expertise, you can be confident that your projects are in the hands of dedicated professionals with a proven track record in designing and optimising industrial processes. We are here to support your project’s success, from concept to completion, by providing innovative and tailored process engineering solutions.

WASTE REDUCTION

Within Projectek, we specialise in providing tailored services to the paper industry, focusing on waste reduction strategies that drive operational efficiency and cost savings. Our expertise encompasses spoil reduction, startup optimisation, and implementing new standard operating procedures to drive efficiency. We understand that even marginal improvements can yield substantial benefits. By leveraging our proven methodologies, we help paper manufacturers uncover significant cost savings. We recognise the value of identifying and implementing efficiencies, whether it’s optimising spoil reduction or finding incremental savings in the production process. Our commitment to waste reduction enables us to support our clients in achieving their financial and environmental goals, while contributing to a sustainable future for the industry.

In the context of manufacturing, wastes refer to any activity, material, or resource that does not add value to the final product or service, and therefore results in inefficiency and increased costs. There are several types of waste in manufacturing, commonly identified using the “Seven Wastes” framework developed by Taiichi Ohno, the father of the Toyota Production System. These seven wastes are also known as “Muda” in Japanese:

THE SEVEN WASTES

OVERPRODUCTION

Producing more than what is currently needed or demanded by customers. Overproduction leads to excess inventory, tying up valuable resources and increasing carrying costs.

INVENTORY

Holding excess inventory can lead to increased storage costs, risk of obsolescence, and decreased cash flow. Inventory that sits idle is essentially waste.

WAITING

Refers to any downtime or idle time that occurs when workers or equipment are not actively engaged in the production process. Waiting wastes time and reduces overall productivity.

MOTION

Wasted movement of people or equipment within the production process. Excessive motion can lead to ergonomic issues, inefficiencies, and potential safety hazards.

DEFECTS

Defects, errors, or mistakes in the manufacturing process result in the production of defective products, leading to rework, scrap, and increased costs.

TRANSPORTATION

Wasted efforts associated with unnecessary movement of materials or products within the production process. Excessive transportation can lead to damage, delays, and increased costs.

OVERPROCESSING

Performing more work or using more resources than necessary to meet customer requirements. Overprocessing adds cost without adding value.

In addition to the Seven Wastes, some manufacturing experts also identify other types of waste, such as:

UNDERUTILISED SKILLS

Not leveraging the full potential of employees’ skills and knowledge can lead to missed opportunities for improvement and innovation.

UNNECESSARY COMPLEXITY

Overly complex processes, product designs, or systems can lead to inefficiency, confusion, and errors.

UNNECESSARY OR EXCESSIVE ENERGY CONSUMPTION

Inefficient use of energy resources can result in unnecessary costs and environmental impact.

Identifying and eliminating these wastes is a key objective of lean manufacturing and continuous improvement efforts. By reducing or eliminating waste, manufacturers can improve productivity, quality, and customer satisfaction while reducing costs and environmental impact.

WORLD-CLASS MANUFACTURING TOOLS & TECHNIQUES

At Projectek, we are dedicated to helping our clients achieve world-class manufacturing standards by leveraging a comprehensive suite of industry-leading tools and methodologies. We understand the importance of efficiency, quality, and continuous improvement in today’s competitive market. That’s why we employ a range of renowned manufacturing tools, such as:

SMED (Single-Minute Exchange of Die)​

By applying SMED principles, we minimise changeover times between production runs, allowing for faster, more flexible manufacturing processes. This reduces downtime, increases throughput, and enhances overall productivity.

5S Methodology

We promote the use of the 5S methodology (Sort, Set in Order, Shine, Standardise, Sustain) to create organised, clean, and efficient work environments. This fosters improved workflow, employee productivity, and safety.

Poka-Yoke (Error-Proofing)

We implement Poka-Yoke techniques to prevent errors and defects at the source. By designing foolproof systems and incorporating mistake-proofing devices, we mitigate the risk of human error, improving product quality and reducing rework.

Kaizen (Continuous Improvement)

We embrace the philosophy of Kaizen, which emphasises small, incremental improvements across all aspects of the manufacturing process. By fostering a culture of continuous improvement, we drive efficiency, reduce waste, and optimise operations.

Ishikawa Diagrams
(Cause-and-Effect Analysis)

Ishikawa diagrams, also known as fishbone diagrams, help us identify and analyse the root causes of problems or inefficiencies. By visually mapping out the contributing factors, we can implement targeted solutions to enhance process performance.

Value Stream Mapping

Through value stream mapping, we visually depict the end-to-end flow of materials and information in a manufacturing process. This enables us to identify bottlenecks, streamline workflows, and eliminate non-value-added activities, resulting in improved lead times and resource utilisation.

These world-class manufacturing tools, along with our deep expertise and experience, allow us to partner with clients in achieving operational excellence. We tailor our approach to the specific needs and goals of each organisation, empowering them to enhance productivity, reduce costs, and deliver high-quality products in a competitive market.”

Please note that the list of tools provided is not exhaustive, and there are other relevant tools and methodologies that can be utilised based on the specific needs and challenges of each manufacturing environment.

Problem Statement, Current State Analysis and Problem Solving

At Projectek, we believe that structured problem solving is key to driving continuous improvement and achieving operational excellence. We understand that identifying the correct problem statement can be a challenge, which is why we follow a structured approach that starts with a thorough understanding of the current state and problem statement.

Our structured problem-solving methodology incorporates a range of powerful tools, including the Ishikawa Diagram, 5 Whys, and other relevant problem-solving techniques. These tools enable us to systematically analyse and address complex issues, from containment to root cause identification and resolution.

We begin by clearly defining the problem statement and conducting a comprehensive analysis of the current state. This involves gathering relevant data, conducting observations, and engaging stakeholders to gain a holistic understanding of the problem.

Standardisation for Sustained Results

Once the root cause has been identified and resolved, we emphasise the importance of standardising the improved process or solution. This ensures that the positive outcomes achieved through the analysis are sustained over time. Standardisation may involve developing standard operating procedures (SOPs), implementing visual management tools, or establishing control plans.

By applying our structured problem-solving methodology and utilising these powerful tools, we help our clients address complex challenges effectively. We empower organisations to achieve sustainable improvements, enhance operational efficiency, and drive long-term success.”

Please note that the list of problem-solving tools provided is not exhaustive, and there are additional techniques and methodologies that can be utilised based on the specific nature of the problem and client requirements.