CLIENT REQUEST
A major food & beverage client was preparing for increased demands in capacity and knew it would require major upgrades to their existing process systems. Due to the complexity of the project, they wanted to verify the major scope requirements through completing some preliminary definition. The request was to create a process production simulation to represent their existing operations and then use the model to determine the full scope of the potential upgrades.

The client also had an existing model that would be assessed and if viable used for this definition effort. The simulation, when finished would inform decisions in the following process systems:

  • Whole milk reception
  • Cream reception
  • Whole milk silo capacity
  • Skim milk silo capacity
  • Cream silo capacity
  • Cold milk separation
  • Cream pasteurization
  • CIP capacity
  • Utility loading

Plus Groups’ Automation/IT team was able to review, test, and make modifications to the existing simulation model to create a more robust model to ensure all identified future process scenarios were captured. During the discovery process, we engage the client to gain a thorough understanding of the processes to be simulated. Through collaboration with both client and Plus Group SMEs our process establishes critical criteria that is used to inform the simulation effort and provides guidance on the use case(s) in which the model would apply.

APPROACH 
The Plus Group has a proven project life cycle that includes discovery, collaboration, ideation and simulation/modeling.

During the discovery process, we engage the client to gain a thorough understanding of the processes to be simulated. Through collaboration with both client and Plus Group SMEs our process establishes critical criteria that is used to inform the simulation effort and provides guidance on the use case(s) in which the model would apply.
During the discovery and collaboration steps, Plus Group builds functional requirement that allows review and alignment prior to investing time in the actual modeling effort. We also establish the various scenarios that first validate and then scale the model for testing new requirements established by the capacity increases. Finally, we optimize the model through initial testing, review of data and observations made during scenario runs.

RESULTS
The client was able to gain significant insight to their existing process systems and make fully informed decision regarding each of the areas listed above. With the confidence gained through this effort the project team built justification for the site’s future development. Further, through phased scenario testing, the client understands the incremental steps to the site’s expansion as was able to create an expansion road map defining what triggers each aspect of the site transformation. Lastly, because of the Plus Group’s modular approach to simulation builds, we can easily adapt the model to various options and additional efforts that may be required in the future.

LOCATION: United States

TOTAL PROJECT CAPITAL: $151, 000

CUSTOMER TESTIMONIAL

 “This factory has an incredibly complex process, so coming up with a master plan to accommodate multiple desired changes along with all the internal and external variables seemed to be an impossible feat at first. Plus Group struck a perfect balance between detailed and high-level approaches in their development and improvement of a model to simulate our system. This approach allowed us to test potential process upgrades across all key scenarios and identify critical gaps to be addressed within our capital project plan.  “Working with Plus Group was an excellent experience; they were organized, thorough, and tenacious in learning our processes and applying this knowledge to refine the model to meet our objectives. I was impressed with the level of detail in their final deliverables, and I had them present the simulation to our leadership team so we can reapply this methodology across the market to better inform long-term business decisions.”
– Confidential Project Manager

 

 

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