Manufacturing Excellence at Start-up

Maximize Plant Performance at Start Up

Does your organization struggle when an expansion is occurring at your facility to meet project and business expectations? Does your workforce dread a start up or are they excited about getting a chance to participate in something new? Instead of dread, use this opportunity to build momentum towards a proactive continuous improvement culture. Can you think of better opportunity to move the culture from reactive to proactive? The whole organization is focused on getting the new equipment running and supplying the product to our customers.

MET DEMAND offers a 30 hour seminar on achieving "Maximum Plant Performance at Start-up". The course is intended for anyone who is responsible for or participating in a project installation and / or start-up and is based on a TPM, continuous improvement, model to minimize life cycle costs.

Develop a Vision of Success- Does everyone have a common vision, direction and expectations? These must be clearly defined and communicated at all levels of the organization.

Understand Potential Start Up Problems- It is not if problems will occur but when they occur. Is your organization prepared to deal with them? The key is to manage these problems proactively and set up contingency plans so your organization is ready to deal with any issue when it occurs.

Who has the keys- Engineering and Operation Ownership?- Engineering and project management owns the management and execution of the capital project by designing, purchasing and building a reliable facility. Operation owns the development of the organization to operate the facility by ensuring qualified staffing, start-up support, operation and maintenance training, maintenance excellence activities, raw material supply, waste disposal, quality systems, business systems and finished goods management. Learn how to smoothly transition from a capital project focus to a Total Plant Performance focus by clearly defining roles and responsibilities for each job and function during the execution of the project.

Precision Maintenance during Construction- Ensure that the construction contracts include precision maintenance techniques during installation, such as, laser alignment of shafts and drives, laser leveling for equipment installation, and following all torque limits. During the time of construction, many future reliability problems can be eliminated with proper quality control and inspection of the work.

Planning for Checkout, Commissioning and Validation- The physical and organizational transformations are done by setting up a structured, systematic approach to ensure reliable capacity at start-up. The approach starts in construction and proceeds through to the day of start-up. Each phase is done with clearly defined objectives and outcomes.

Plan Training for All Functions- There are new technologies, business systems, vendors, maintenance and operating tasks which need to be understood and owned by the appropriate personnel. How do you identify specific training needs? Ensure the standard work instructions are developed to meet the need? Develop effective training? Manage training costs?

Managing Extra Start up Resources- This is a key subject because most organization will share resources from one facility to assist another facility in executing a large capital project. Managing the perception of these resources is critical in managing the business perception of how well the project is being managed.

Start up Costs- What does it cost to do it right in the beginning? A whole lot less cost than when you have to do it over and over again in the future. This start up training is based on the concept of minimizing the life cycle cost of equipment. This requires resources to develop, plan and execute good organizational change management which has an upfront cost but generates a long term saving vs. the alternative.

Workforce Morale- You can not have a successful start-up unless you have engaged people. People are engaged when they understand the direction, expectations, and see consistent follow-up. Workforce Morale is a measure of the workforce ownership.

Maintenance Assuring Capacity- There are 11 specific tasks which need to be performed for every asset being installed on the project. All part data needs to be in CMMS. Spare parts are recommended and on site. All equipment data is set up in the CMMS. Equipment documentation is available. Maintenance training is complete. Preventive maintenance tasks are developed and in CMMS. Lubrication tasks are in CMMS, Etc.

Start Up Safety and PSM- Write this down, you cannot have a successful project if there is a lost time accident, an environmental issue affecting our neighbors or a product issues causing injury to a customer. Developing a comprehensive safety program is dependant on the behaviors of the work force and during the start up of a project there are many activities and situations which are going to occur which need to be managed by the workforce. How do you raise the awareness of the workforce and make safe behavior the foundation of the project team to minimize safety and environmental risks?

Please e-mail us your question or comments on this seminar at


Home | About | Contact | Services | Training

P.O. Box 385
Charleston, Il.