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| New Plant/New Technology Start-Up A proven approach to on-time implementation PROCESS SUMMARY The start-up of a new plant, the expansion of an existing plant, or the introduction of new manufacturing technologies imposes a tremendous burden on a company’s resources. There are several key elements that must be planned, scheduled and implemented in concert to bring the project to a successful completion. In most situations, the emphasis is placed on the physical construction required; the selection, purchase and installation of the equipment; and the identification and formulation of the process control measures needed to produce a quality product. Seldom is the same consideration paid to defining the staffing levels and planning the recruitment and training of the personnel who will be needed to run the equipment. As a result, even though the physical resources may be in place on schedule, there is usually a long ramp-up period for the operating and maintenance skills to reach the same level of productivity. For any new start-up to be effective, the people side of the process must be as well planned and controlled as the equipment side. Start-ups usually involve work force transitions or increases. When coupled with the introduction of new technology, a structured Human Resources plan is required to develop the knowledge and skills needed to support the normal, special and troubleshooting routines that are required to run and maintain the new process. The start-up process can be compounded when the company is also introducing new manufacturing procedures, such as JIT, Team Manufacturing, Pull Systems for inventory control or pay system changes, at the same time. KEY FEATURES OUR APPROACH Our work is a combination of Training, Industrial Engineering and Personnel Management disciplines, supported by the solid manufacturing experience of our results-oriented specialists. Our staff members have been carefully trained to assist our client companies to introduce changes and obtain improvements with the cooperation and understanding of the client’s staff. The first step is a discussion with one of our senior specialists, followed by a short survey to determine the scope for our work, the benefits that may be expected, and the costs involved. When invited to work with a company we do not install “package” programs – neither do we merely make recommendations. Following proven principles and techniques, we assist clients to develop programs suited to their needs and personnel, with full participation of the staff concerned. We then work with them to achieve the expected results. A major aspect of our approach is to give thorough training to members of the client’s staff so they may continue the work successfully after we leave. In addition to our normal full-time assignments, our specialists are also available for occasional audits, advisory visits and in-house workshops and seminars. CLIENT BENEFITS o Performance goals reached ahead of schedule. o Increased market share and customer orders. o On time deliveries with reduced in-process inventory levels. o Controlled and predictable ramp-up to full production. o Improved Quality and Safety. o Reduced start-up costs. o A role model Training System for future start-ups. |
Services
Charles Brooks Associates, Inc
Analysis of existing plans for facilities completion and production ramp-up.
Development of a start-up plan and schedule to coordinates employee recruitment and
training with the physical build-up of the manufacturing resources.
Coordination with equipment vendors and existing facilities to identify the knowledge and
skills needed to operate and maintain the equipment.
Selection and training of a Training staff to train the new employees.
Identification and documentation of Standard Operating Procedures.
Incorporation of changes in management philosophy and procedures.
Development of a training plan and schedule.
Researching the availability of outside training funds from local and state government.
Directing and monitoring the training process and measuring training results.
Development of a start-up plan and schedule to coordinates employee recruitment and
training with the physical build-up of the manufacturing resources.
Coordination with equipment vendors and existing facilities to identify the knowledge and
skills needed to operate and maintain the equipment.
Selection and training of a Training staff to train the new employees.
Identification and documentation of Standard Operating Procedures.
Incorporation of changes in management philosophy and procedures.
Development of a training plan and schedule.
Researching the availability of outside training funds from local and state government.
Directing and monitoring the training process and measuring training results.
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