1. Situation
In the rapidly evolving biotechnology sector, our client specializes in the cutting-edge field of bio-conversion and bio-reproduction using black soldier flies (BSF). They have successfully established an efficient biological cycle and are now seeking to scale up their operations to industrial levels. The Client reached out to WorkNomads to conduct an engineering audit to investigate and propose what it needed to fulfil the Client’s ambition to scale and be the best in class.
2. Team of experts
WorkNomads appointed 6 specialists all working remotely or hybrid from Bulgaria with frequent onsite visits and client residency periods.
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Automation Engineer
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HVAC Engineer
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Mechanical Design Engineer
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Process Engineer
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Project Manager
3. Process
WorkNomads was requested to deliver in a systematic and understandable way the complexity of the Client’s production in order to help them focus on step-by-step production ramp up.
The Client faced a critical challenge in their production operations, a lack of clarity on the maximum output capacity of their current equipment setup.
They needed a comprehensive cycle diagram to visualize the interconnections between different stages of production and understand the impact of each process on overall efficiency.
Specific focus was on the following topics:
- Reliance on manual operations leading to inefficiencies and potential bottlenecks;
- Resource allocation of electricity, water and steam
WorkNomads was appointed to provide a detailed analysis and identify the actual potential output of the existing setup and outline necessary future investments.
The WorkNomads team started the assignment with the following objectives:
- Maximize efficiency: gain a clear understanding of production processes and systemize data flows;
- Optimize equipment use: identify the potential of existing equipment and outline necessary upgrades;
- Enhance productivity: improve operational efficiency and reduce losses.
Our comprehensive analysis focused on evaluating the current capacity of their equipment and providing a detailed overview of the entire process layout. We constructed a mass balance and a Sankey diagram to visually represent material flows and outputs, alongside a utility matrix outlining all current resources such as electricity, water, and steam. This analysis helped in assessing the resource capacities available to the factory.
Our team continued its assignment as follows:
- Creation of detailed process layout to visualize interconnections and identify bottlenecks;
- Introduce a mass balance and sankey diagram to represent material flows and outputs clearly;
- Provide utility matrix: outlined current resources and their capacities to optimize resource allocation;
Finally, WorkNomads started the implementation process, armed with a holistic view of the production processes, we designed a cycle diagram highlighting and addressing critical bottlenecks.
4. Conclusion
Our engineering audit culminated in the delivery of a suite of critical engineering documents, including a utility matrix, process layout, mass balance, Sankey diagram, and cycle diagram. We outlined strategic improvements to achieve maximum operational capacity and assisted the management team in developing a ramp-up schedule and relevant KPIs to sustain lean growth.
The Client was empowered with a comprehensive understanding of their production landscape, including potential bottlenecks, essential equipment upgrades, and optimization strategies, paving the way for enhanced operational efficiency and competitiveness in the biotech industry.
