Most manufacturing companies are so focused on day-to-day operations that they miss important opportunities for process improvement. Every company has unseen opportunities and Integrated Technologies, Inc. (ITI) can help companies realize these opportunities.
A Process and Facility Opportunity Assessment (PFOA) is a powerful and cost effective process and facility improvement methodology designed to efficiently identify opportunities. Common opportunities for improvements in surface finishing facilities include: process flow improvements, documentation, methods and procedures, preventative maintenance, corrosion management, and rinsing design. Implementation of these types of improvements can improve operations by reducing labor, material, energy, and environmental costs and can extend asset life cycles. Many opportunities can be realized by improvements in technique only, and ROI can be days, weeks, or months, as opposed to years. Please review our White Paper on PFOA for more information on this service.
Every company has hidden risks, typically in the form of environmental, health & safety, and business interruption (asset condition) risks. With Risk Assessments, Integrated Technologies, Inc. (ITI) can help companies identify these risks. Some examples of common risks found in wet process facilities include: disruptions to production due to equipment failures or poor equipment design; corrosion to tanks or structure elements; and environmental non-compliance due to poor housekeeping practice or inadequate equipment design. Identifying these numerous risks is critical, as they can have significant impacts on production, revenues, labor costs, material utilization, insurability, delivery, and customer satisfaction.
Energy costs are typically a major component of overall operating and maintenance (O&M) costs for surface finishing systems. There are substantial opportunities for cost savings, for new or existing systems, through good design, process optimization, and management that consider factors that impact energy usage. Energy is consumed in a range of surface finishing processes, including: process solution heating and cooling, fluid and material handling, rectification, solution agitation and filtration, ventilation and make-up air processing, waste and by-product management systems, and substrate/finish heat treatment and drying. Assessment of these existing processes provides information for estimating the savings/payback opportunity for energy efficiency process improvement.
Asset Management Planning
Manufacturing Asset Assessment & Planning (MA2P) is a comprehensive process and strategy to optimize the life cycle costs and improve the reliability of manufacturing assets. MA2P is a unique tool developed by Integrated Technologies Inc. (ITI) to assess the physical condition, operational efficiency, impact of failure, and relative risk of failure for process equipment, physical plant, and plant systems. Life cycle costs and risk can be managed with effective planning. MA2P deliverables include a quantitative assessment of condition and risk and recommendations to reduce operational life cycle costs and mitigate risk. Investments in MA2P can extend the life of manufacturing assets, reduce the risk of business interruption and EH&S system failures, and dramatically improve operational efficiency.