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Production Schedule

As always the examples below are not complete. Your schedule will have to be much more detailed than the examples we show here. Below, you will find the steps for how to make production schedules.


Ah! You're getting to the nitty gritty now. You have a deadline and in order to meet that deadline and, of course, stay within budget, you need a schedule. More than one producer has said, "We live or die by the schedule" and meant it. Not only that, the Studio finds a written schedule reassuring--a sign that the production team has everything under control.
Keep in mind that the production schedule is not written in concrete. You may complete some tasks earlier than expected(those will call for a celebration) and other tasks will be delayed(in those cases try not to panic). The schedule will help keep you on track no matter what happens.
There are a couple of different kinds of schedules you can use. The PERT chart is one and the Gantt is another. You probably will want to use both of them.
The PERT (Project Evaluation and Review Technique) chart is a sort of flowchart of all the activities or tasks in the production phase of your project. The relationships between activities is clearly shown, completion times and names of persons assigned can be attached to each task. Except at the beginning and end of the chart, each task should be preceded and followed by another task. Tasks can also branch out and travel their own paths rejoining the main path at some later point. Any milestones such as points of review or completion can be indicated as well.
The following example is the original PERT chart for the whole "Understanding Your Automobile" project. This gives you an idea what a PERT chart looks like. Your chart will look somewhat different because it will start at the Production phase of your project and contain a lot more detail than this one:


The Gantt chart is a timeline chart. It clearly shows when each task is to begin, the time it will take to complete each task, and which tasks will be going on simultaneously. You may want to use more than one level of Gantt chart. One chart may show the whole production phase from beginning to end. Another may show two or three weeks' activities. Another might show the current week's tasks. The example below is a two week chart from the production phase of the "Understanding Your Automobile" project:

How to Make PERT and Gantt Charts
Do the first three steps before beginning to develop either type of chart.
Use whiteboard, flipchart sheets or other large space.
Make a list of all tasks or activities involved in the production, post-production, and Premiere phases of your project.
Put them into sequential order.
Now draw your PERT chart on the board. Your first pass will probably not be your last. The chart doesn't have to be perfect the first time. Be prepared to adjust tasks once you see the sequence laid out.
Next you will have to estimate the time it will take to complete each task and put the time next to that task on your list. You'll be using that information for the Gantt chart as well.
Label each task on your PERT chart with the time you determined in step #5.
Readjust the sequence of tasks as necessary.
Now determine who is responsible for each task on the list and put his/her name next to that task.
Label each task on your PERT chart with the name of the person responsible.
Readjust sequence, if necessary, until all team members agree to its accuracy.
Once your PERT chart is complete, if it is on a board where it can't be saved, redraw it on a piece of paper(the bigger the better) so that it can be posted during team meetings, or redraw it and make copies for your team members.
Now, using the times on your list and the sequence in your PERT chart, you can draw your Gantt chart.
Decide at what level you want to view your timelines--weekly, monthly, whole project. It is recommended you start with an overview of the whole project.
Label the chart across the top by week. Use start (Sunday) or end (Saturday) dates for each week.
Label the chart along the left side with all of the tasks(or consolidate tasks under headings that make sense for an overview).
Now draw horizontal bars for each task beginning at the start date for that task and ending with the completion date for that task.
When you have completed a timeline for each task and all team members agree to its accuracy, follow the same procedure in step #11.
Draw a Gantt chart for the first week's activity by putting each day of the week across the top and each task for the week along the left side. Then follow procedure in step #16.
Label bars with name(s) of team member(s) responsible for that task.
Save chart and make copies for all team members.

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Cost Analysis

SuperPro and EnviroPro Designer perform thorough Cost Analysis and Project Economic Evaluation calculations and generate two pertinent reports. The reports are generated in Text and Spreadsheet formats. The list of calculated items includes:
Equipment Purchase Cost Table


SuperPro is equipped with built-in functions that estimate equipment purchase cost based on size, material of construction, and other characteristics. The user has the option to specify his/her own equipment purchase cost or provide his/her own parameters (in power-law format) for estimating the cost. Starting with version 5.0, the user may create an equipment database (in MS Access format) and store equipment-related info (including cost data) in a centralized and easily retrievable way.


Fixed Capital Investment Table
The estimation of the fixed capital investment is done using multipliers. The "Installation" multiplier is equipment specific. All other multipliers are process specific. The user has the flexibility to modify all the multipliers. Starting with version 5.0, all the fixed capital investment multipliers are stored in the database as part of the definition of a Manufacturing Facility. Associating a recipe (process) with a manufacturing facility in the database enables the user to use all the cost parameters of that facility for the cost analysis of that process.

Labor Cost Table
The labor demand is estimated by summing up the labor requirement of each operation. Again the user has the option to override what the program calculates. The labor unit cost and the multipliers for fringe benefits and supervision are specified at the Section level. A Section is a set of unit procedures that can represent an identifiable part of a long process. For instance, the flowsheet from which the following table was extracted was divided into four sections (Product Synthesis, Isolation and Purification, Final Purification, and Crystallization).

Raw Materials Cost Table
The amount of raw materials is calculated based on the material balances. The unit cost is retrieved from the component database. The user has the option to override the unit cost (purchasing price) in the component database.

Other Operating Cost Tables
The software also generates tables for the cost of Consumables (e.g., for periodic replacement of chromatography resins and membranes of membrane filters), the cost of Waste Treatment and Disposal (distinguishing between solid, liquid, and vapor emissions), and the cost of Utilities (e.g., heating, cooling, power).
Annual Operating Cost Summary Table

Profitability Analysis Table
The profitability analysis table includes info on capital investment, annual production, unit production cost, revenues, profit, gross margin, return on investment and payback time.

Cash Flow Analysis Table
The cash flow analysis table provides financial data for the entire life of the project. Based on the Net Cash Flow, the program calculates the Internal Rate of Return (IRR) before and after taxes and the Net Present Value (NPV) of the project for three different values of discount interest (that can be specified by the user). The same report includes info on the breakdowns of capital outlay and loan payment (if part of the fixed capital investment comes from borrowed money).

Itemized Cost Report (2nd Report) Tables
This report focuses on breakdowns of operating cost per flowsheet section and item. As mentioned above, a section is a set of unit procedures that can represent an identifiable part of a long process. The table below for instance displays the cost associated with the "Product Synthesis" section. The various cost items are listed on the left-hand-side and the costs are provided in $/kg MP (MP stands for main product that defines the scale of the process), $/Batch (or $/h for continuous processes), and $/Year.

The following table displays a summary of the operating cost for the entire process (flowsheet).

The following table provides breakdowns per flowsheet section and item. Each column represents a section and the "%" contribution of each section is shown on the bottom row (bluish background). For instance, the Synthesis section is responsible for 37.23% of the overall operating cost. By looking at this table, one can quickly identify the economic "hot-spots" of a process, which are the expensive parts of a process.

The last table of this report provides a breakdown of raw materials cost per section and per item.

Sensitivity Analysis Studies
After a model for the entire process is developed in SuperPro Designer, the user can use the tool to ask and readily answer "what if" questions and carry out sensitivity analysis with respect to key design variables. For instance, the figure below shows the unit cost of a therapeutic monoclonal antibody as a function of product titer in the broth (100, 250, and 500 mg/L) and as a function of production rate. The results of such analyses can assist in project selection and R&D planning.

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