Pre-Project Planning
Consulting Services for Primary, Secondary, and Tertiary Packaging
Pre-Project Planning
Consulting Services for Primary, Secondary, and Tertiary Packaging
Team Leader - Les Patkos
30+ years of Packaging Systems design, integration, equipment sourcing and FATs, project management, scheduling, installation management, and commissioning oversight. Project experience across a multitude of Fortune 500 CPGs, Food Service, PHARMA, Manufacturing, and Distribution.
Food Packaging Experience including... Bakery Products, Frozen Dough Products, Confectionary, Pizza, Bagged Salads, Frozen Vegetables, Prepared Salad Varieties, Prepared Sandwiches, Fresh and Frozen Meals, Meal Kits, Meat & Meatless Products, Dry Foods, Poultry Products, Fish Products, Snack Products, Pet Foods, Coffee, Yogurt, Ice Cream.
Packaging Formats Experience including.... Vertical Form Fill Seal (Baggers), Horizontal Form Fill and Seal (Wrappers), Pre-made and HFFS Pouching, Thermoform MAP Packages, Clamshells, Tubs, Plastic or Fiberboard Primary Trays, Cartoning, Robotic and Conventional Case Packing, Display Tray Loading, Robotic and Conventional Palletizing, and Stretch Wrapping. Also diverse experience in ancillary packaging equipment including Checkweighing, X-Ray inspection, Vision Inspection, Print and Apply Labeling, and Date Coding.
Contact: lpatkos@pkgsyseng.com
Pre-Project Planning Services
PRE-PROJECT PLANNING..... for Major New Initiatives
Front-End Loading (FEL), also referred to as pre-project planning (PPP), feasibility analysis, conceptual planning, and early project planning, is the process for conceptual development of projects in many industries such as CPG products, food industry, and pharmaceuticals. This involves developing sufficient strategic information with which owners can address risk and make decisions to commit resources in order to maximize the potential for success.
FEL 1 – Conceptual Consulting… Assessment of Options with Order of Magnitude Costing
- Initial Project SOW – Develop SOW (Scope of Work), define success
- Preliminary Process Definition – Major processes and required rates identified
- Preliminary Concept Layout – Equipment placeholders, conveyors, circulation
- Order of Magnitude Cost – Develop +/- 50% Budget Costing Only
- Major Milestone Schedule – Approximate schedule based on long lead items
FEL 2 – Feasibility Consulting… Development to Obtain Budget System Cost
- Preliminary Process Flow Diagrams – All processes and rates confirmed
- Preliminary Equipment Definition – Identify equipment and develop specs
- Preliminary System Layout – Layouts developed to qualify system operations
- Preliminary Schedule – Overall project schedule with equipment deliveries
- Preliminary Network Diagram – Shows how equipment and line are integrated
- Equipment Selection – Preliminary RFQ's, secure equipment budgets +/-30%
- Budget System Cost – Develop +/- 30% overall system budget costing only
FEL 3 – Detailed Consulting… Refined Layouts with OEM info, CAPEX Costing, and Scheduling
- Final Process Flow Diagrams – Processes & rates confirmed showing details
- Final System Layouts – Final OEM equipment, conveyors, paths, elevations, details
- Utility Needs – Identifying power, compressed air, and other utilities
- Final Network Diagram – System integration and plant networking diagram
- Device Layout– Show OEM panels, devices, sensors, HMIs, pushbutton stations
- E-Stop Layout – Identify owner's desired Global or Zoned E-Stop Philosophy
- Equipment List – Identifies equipment in project with utility requirements
- Installation Bids – Drawings and RFQs to site contractors for quotes
- Equipment Purchase Consulting – Full RFQs Secure bids, bid tab, decision matrix
- CAPEX – Final System Costing +/- 10% inclusive of all equipment and services
- Final Schedule – Gantt with detail level execution activities and dependencies
- Final Project Charter – All details of project execution, schedule, and costs
PRE-PROJECT PLANNING... for Incremental Line Upgrades
Packaging Equipment Changes or Upgrades - Consulting Services
- Upgrades to existing packaging lines or equipment
- Add a new equipment unit to your line
- Add inspection equipment... X-Ray / Metal Detection / Checkweighers
- Vision Inspection System options analysis
Line Assessment - Consulting Services
- Survey of existing packaging line with data collection
- Value Stream Mapping
- Time Studies and Analysis
- General Assessments
Equipment Sourcing - Consulting Services
- Help source potential equipment vendors
- Prepare equipment RFPs and issue to potential suppliers
- Review and validate proposals
- Prepare bid tabulation of offers
- Prepare a Decision Matrix as owner's decision aid
Accumulation System Additions - Consulting Services
- Assess needs for accumulation
- Prepare a simple simulation showing efficiency adding accumulation
- Source potential accumulation options
Project Consulting Services
General Project Management - Work as Owner's Representative
- Project Control - Management and coordination throughout project life cycle
- Equipment Procurement – Develop purchase requisitions and process orders
- Equipment FATs – Coordinate and execute Factory Acceptance Tests
- Project Schedule Control – Maintain Gantt chart of project schedule
- Project Financial Management – As customer’s agent to monitor and control
Final Project Design Reviews - Work as Owner's Representative
- Final Designs - Review as required to execute project from start through installation
- Conveyor Layouts – Conveyors to link and integrate equipment are designed
- Custom Devices – Review developed concepts for special automation devices
- Equipment Approvals – Validate vendor scope and specifications are met
- Controls & Integration – Help develop network diagram and integration plans
- Functional Description - Develop detailed description of operation for system
During and After Installation - Consulting Services
- Coordination & Planning – Help develop and monitor schedule
- Commissioning & Training – Consult with customer team and technicians
- CQV – Monitor / Consult ... Commissioning, Qualification, Validation activities
- Project Closeout – participate with team closing out project / lesons learned