Audit Process
Audit Preparation
- iZ Systems provides a Pre-Audit form and check lists to insure the facility is properly prepared for the audit in order to minimize wasted time and maximize the value for plant personnel. Other than basic data, this form explains and encourages the installation of test ports as required based on the specific system configuration.
- iZ Systems also provides an Audit In-briefing Letter to assist in gaining departmental cooperation and engagement in the audit process. The in-briefing and out-briefing are critical to gain organizational momentum so that the audit results can be implemented.
- Conference call to confirm that the facility is prepared for the audit. This can include a web demonstration of the audit process and automation systems if appropriate.
On Site Work
The typical schedule for a full week audit will be similar to the following:
- Day 1 – An In-briefing should be held to explain our audit process and methods and schedule appropriate support and resources with the plant. Additionally, the first day will be spent installing data loggers and other test equipment. Supply side equipment evaluations are conducted including compressor tests, pressure drop measurement, dryer and filter performance, and control evaluations in the compressor room. The availability of the compressor room operator and/or engineer for discussion is helpful but no full time effort is required.
- Day 2 - will be spent completing any remaining supply side work to confirm preliminary data logging results. Additionally, an overview of the production processes and how they relate to the supply side analysis will be conducted. This requires the assistance of maintenance or production personnel who are familiar with the process areas and any problems which may exist or occur intermittently.
- Day 3 - will be spent conducting a detailed evaluation of production processes. Normally, we need to spend about a hour or two in each process area or production line with the assistance of a person knowledgeable in that area.
- Day 4 - will be spent completing the production process evaluation and finalizing any data collection required and confirming and discussing any other issues which have arisen.
- Day 5 - An Out-briefing w be held and should include representatives of all departments with a direct interest in the performance of the air system. The plant manager may want to attend because of the potential for initiating a significant project for reducing costs and improving production and quality.
Final Analysis and Report
The final audit report is normally completed within 2 weeks of the on site work and contains a summary of all data gathered and recommendations in sufficient detail to allow the client to execute the project on their own if desired. Sample audit reports are available upon request. Each report will contain the following at a minimum:
- Executive Summary
- Demand Issues and Solutions
- Supply Issues and Solutions
- Distribution and Storage Issues and Solutions
- Compressor Performance Table showing performance relative to OEM specifications
- Power and Volume Tables detailing the efficiency of each compressor as it operated
- Existing Processes Flow Diagram
- Energy and Financial Calculation Tables
- Proposed Process Flow Diagram
- Prioritized Action Plan with estimated costs
- Graphs of the Existing Performance for each production load identified
Audit In-briefing
It has been our experience that a briefing session that includes decision makers from each production unit at the facility, in addition to management, engineering, and maintenance should be held the first day of the audit. A brief explanation of cause and effect in an air system will allow production personnel to cooperate with the analysis effort in terms of identifying problem applications, waste, etc. Explaining technically, how most problems in an air system are caused by the applications and not the compressors provides production personnel with a new insight to recurring problems and encourages their participation in the analysis. We will also discuss organizational priorities for the compressed air system which can have a significant impact on the proposed solutions provided. The in-briefing will last less than 1 hour and will maximize the value of the audit.
Audit Out-briefing
An out-briefing should be held the final day of the audit to review the opportunities identified and the implementation effort required. The recommendations will be presented to the management group in terms of the priorities set at the in-briefing including the investment and payback anticipated. This will also provide an opportunity to discuss any concerns with the conclusions or recommendations while we are still on site. The out-briefing is intended to create momentum for implementing the recommendations and a final opportunity to examine any unidentified issues.