Our core service offering includes:
A Site Master Plan (SMP) is a valuable tool in maximising any site’s manufacturing / production potential. A SMP sets out to define and incorporate the client’s short, medium and long-term production objectives into a clear, logical future strategic development framework in a format that all the stakeholders can understand. The development framework provides a baseline against which all future projects can be measured, allowing them to fully consider the overall site strategy and reduce the risk of future constraints. In the ever-changing environment of manufacturing it is essential that SMP is a ‘live document’ that can be easily adapted (and updated) to meet changing market requirements for new and/or value-added processes. The site is reviewed from a holistic perspective considering factors such as site location, infrastructure, manufacturing volumes, expandability, energy, water, waste, transportation, Good Manufacturing Practice, material flows, personnel requirements, warehousing etc. The SMP process is extremely collaborative with the objective of getting full stakeholder buy-in. The end result is enhanced long-term site viability through the accommodation of multiple expansion direction and scheme scenarios. These incorporate the latest in lean manufacturing and process design principles to ensure maximum cost efficiency and sustainability for the client.
The process is the heart of any manufacturing facility. It is thus vitally important that the process is designed effectively. Front End Factory specialises in the detailed design of processes that provide the client with the optimal blend of flexibly, product quality, reduced conversion costs and manufacturing repeatability. All of our designs apply lean manufacturing principles as well as international current Good Manufacturing Practice (cGMP) and optimise operability and maintainability of the plant as a whole.
When designing a manufacturing / production facility it is extremely important that the facility is designed to complement the manufacturing process it contains. Front End Factory’s ‘inside out’ approach focuses on just that. We rely on Good Manufacturing Practice (cGMP) and lean manufacturing principles to optimise flows of people, material and waste alike, as well as to derive the best benefit from area synergies and adjacencies in the facility. This process ultimately results in a facility design that is optimal, economical and sustainable.
Our utilities and pipework design is focused on developing solutions that reduce energy usage, reduce waste, improve cleanabilty and allow optimal maintainability of the system. All of our solutions aim to have a positive impact on product conversion costs as well as improved plant operations.
Our thorough knowledge of the industry as well as processes allow us to effectively specify, identify and source the optimal equipment for the client application. We are also able to assist the client in identifying any gaps in the services and equipment supplied. In doing so we provide the client with sound impartial technical advice to ensure that the client’s expectations are fully met when the equipment is installed and commissioned. This is further complemented with a full suite of quality assurance services (see below).
The product conversion cost and raw material cost are instrumental in the product’s market competitiveness. Understanding the CoG of manufacture and the effect of any process / facility improvement on it, provides a powerful tool for the client to quickly decide on the viability of the project. Front End Factory provides the capability to derive, understand and analyse the current CoG of products as well as predict the affect of a given project on the product CoG.
One of the key metrics in assessing project success is the return on capital investment of a project. We provide a full suite of project life cycle costing and analysis tools, which allow the client to rapidly determine the project’s financial viability at any time during the project life cycle. If the project at the outset is deemed feasible we also offer a service in developing a project business case, both for projects that will be funded internally and for projects that are funded by a 3rd party.
3D Modelling or Building Information Modelling (BIM) is useful in design simulation and coordination. BIM provides a visual tool that can be used to present simulations of the facility, identify clashes of services as well as review constructability, maintainability and operability of the facility / process prior to orders being placed. In addition to this, during the construction phase the model can also be used to track installation progress and assess the cause and affect of any changes. Front End Factory provides a full BIM modelling service to our client, incorporating the design of the engineers, suppliers and other professional service providers.
Based on the nature of a project there are a variety of project incentive mechanisms available. We have a sound knowledge of these mechanisms and are available to identify and advise on mechanisms that might be suitable to the client’s application.
The project execution strategy governs the methods on how to execute, monitor, and control the project. The strategy is used in communication with all the stakeholders ensuring that everyone is aware and knowledgeable of project objectives and how they will be accomplished. Our integrated knowledge of light industrial / manufacturing projects allows us to provide the client with experienced input into their project execution strategies.
In order to be able to manage the project correctly and to deliver the project in the most economical manner the procurement strategy needs to be customised around the particulars of the project. In order to reduce project risk, Front End Factory, having a detailed understanding of the construction process, is able to advise the client on how to best to divide work packages and appoint the various contractors.
We have extensive experience in advising clients on the technical aspects and structure of contracts, for equipment procurement. This guarantees contractor performance and streamlines the project management aspects of the project.
Whether we are responsible for the design or the design is a service supplied by others, we offer a suite of design reviews developed in order to optimise plant productivity and reduce project and manufacturing risk. We can provide services to review:
During implementation it is important to ensure that the design is being implemented in accordance with the Engineer’s intent and specification. Part of our service offering is monitoring the design / fabrication / construction / installation / commissioning and validation process. This includes:
Although Front End Factory is not considered a multidisciplinary consultancy we can offer our clients the option of a single point of contact and responsibly with regard to the design aspects of the project by managing and coordinating the design of other project consultants and suppliers on the client’s behalf.
Our Project Management skill set is based on a detailed understanding of a manufacturing environment and the challenges of keeping a Brownfield’s site operational in order to maintain predefined outputs and meet production targets whilst effectively expediting the project. Our implementation methodologies are based on the specific drivers of the project, in order to achieve the most value-added outcome for our clients.
In projects for which we are not appointed for the design aspects we can offer the client a service as an independent technical advisor to ensure that the technical and building contractors are adhering to the project specification.
A principal agent is an arrangement in which one entity legally appoints another to act on its behalf. In a typical contract between a client and contractor, it is often important that a third party is appointed to act impartially in dealing with contract disputes and payment. Front End Factory has the experience to fulfill this role both in terms of the FIDIC suite of contracts and the JBCC suite of contracts.