Accurate accounting of feedstock inputs, product outputs and manufacturing losses is critical to maximizing operational and financial performance. A plant-wide production accounting system is the first step towards any loss control initiative. We offer state-of-the-art technology that enables production accounting and data reconciliation. In addition, we can provide loss studies which incorporate benchmarking performance against best practice, and development of product loss management programs.
The key benefit of our products and services is the ability to rapidly identify operational issues at plant or unit level resulting in losses, and to ensure that data used for plant optimization or financial reporting and invoicing is accurate and reliable.
Production accounting: Mass balance and data reconciliation
ANCAP, the national oil company of Uruguay, approached KBC as they were looking to replace their obsolete production accounting systems. The new system would need to cover ANCAP’s hydrocarbon business consisting of a crude oil reception terminal with a total capacity of 536,000 m3, an oil refinery with a capacity of 50,000 b/d and 6 distribution plants for refined oil products located strategically throughout the country.Continue reading 'Production accounting: Mass balance and data reconciliation'
Any data-driven approach for continuous improvement in manufacturing requires definition, ongoing tracking and reporting of key performance indicators (KPIs) against targets. What cannot and is not measured cannot be improved. We offer deep industry and operations domain knowledge to ensure you focus on the right KPIs and set realistic operating targets. Many of our software applications include robust built-in data reconciliation algorithms to eliminate interpretation errors due to bad or missing data. We provide tools to steward operations conformance against targets and constraints, while building up a practical knowledge database.
Feedstock is the biggest operating cost for most plants. A plant’s yield, reliability, energy efficiency and environmental performance can vary drastically depending on the processing of different feedstocks and associated plant processing constraints. We offer deep know-how of industry and production economics, coupled with high fidelity simulation models to allow accurate prediction and optimization of feedstock choices.
Sub-optimal process configurations and operating conditions can result in off-spec or inconsistent product, excessive energy costs, unintended losses and unplanned shutdowns – all of these have a significant impact on plant economics. We offer high fidelity simulation models of process facilities to faithfully represent reality, utilizing fundamental chemical and mechanical principles to create accurate digital twins of process facilities. Using these models, our subject matter experts provide advice and opinion, based on deep operating and engineering domain knowledge, on optimal plant configurations and operating conditions to enhance yield performance and throughput.
Energy usage in process facilities can account for up to 50% of operating costs and is a major driver of CO₂, SOx and NOx emissions. Yet striving for improved energy performance alone can have a highly detrimental impact on yield performance. We offer industry-leading energy and utility system optimization technologies and consulting advice enabled to identify a multitude of cost, environmental and operating improvements that balance the yield-energy trade-off.
Distribution and supply chain optimization
Successfully fulfilling contracts and maximizing market opportunities requires highly visible, flexible and responsive distribution and supply chain management. We offer non-linear process simulation technologies that enable optimal feedstock selection, coupled with technologies that allow plant personnel to schedule and simulate operations on an integrated supply chain topological model, allowing quick identification of potential imbalances between interdependent operations. For suppliers to other producers we also offer cloud-based services to monitor product inventories and process operations in your customer’s facilities to extend the visibility of your supply chain beyond the plant.
Asset integrity assurance
Manufacturing facilities only generate value when they are running. Asset reliability is vital for achieving this. We offer consulting solutions focused on asset strategy, leadership alignment and governance model development, through to reliability assurance, online maintenance and shutdown maintenance support.
Organizational competence and alignment
High-performing businesses need operating models in which their people are aligned to strategic objectives. High-level performance is achieved through the optimal balance of centralization and empowerment, together with effective cross-functional cooperation between business units. We offer consulting solutions focused on achieving strategic leadership, delivering organizational change management and human performance improvement.