SuperPro Designer® SuperPro Designer® is a valuable tool for professionals involved in process development, process engineering, and manufacturing. Empowering Process Solutions

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Achieving operations goals and improving production performance can be a difficult task without a clear and detailed understanding of the facility functionality. Not having a common database for operations information and detailed process visualization can result in decreased productivity and unnecessary costs. SuperPro Designer® and SchedulePro® are highly effective modeling and scheduling software programs that are designed to help you improve the efficiency of your manufacturing process by tracking product streams, waste streams, labour and utility consumption. These two programs have been extensively used as an engineering design tool in industry, however they are much more than that. The information generated by SuperPro Designer® and SchedulePro® provides the user insight and possibilities for improvement in all aspects of a manufacturing facility. For example, the Accounting departments could use SuperPro Designer® and SchedulePro® for economic evaluation and profitability analysis of manufacturing processes. The Operations group would find SuperPro Designer® and SchedulePro® useful for to optimize the use of materials, equipment, resources and labour, ultimately saving both operating time and cost of operation. The Quality Assurance group would benefit from the programs by enhancing existing quality systems such as HACCP, Total Quality Management (TQM), SOP's and ISO. What area of involvement gets your attention?

Engineering-Related Features and Associated Benefits

• User interface process simulation - enables quick and effective generation of flowsheets
• Models for over 140 unit procedures/operations - provides flexible models applicable to most processes
• Rigorous reactor modules showing materials and energy balances of integrated processes - producing various modeling scenarios for quick, cost-effective evaluation
• Extensive chemical components and mixtures database - allows users to customize their flowsheets with applicable raw materials and components
• Extensive equipment and resource database - permits analysis of real process systems and equipment sizing and costing based on either mass and energy balances or user-defined volumes
• Calculation of user-defined volumes - ensures they are within the process limits
• Cycle time analysis - aids in pinpointing opportunities for cycle time reduction for increased productivity and cost savings
• Uncertainly and variability analysis used for planning what-if scenarios and optimization of overall processes - resulting in more streamlined operations
  • Monte Carlo simulation can be performed using SuperPro^® with Crystal Ball^® from Decisioneering Inc. (Denver, CO)
• OLE 2 support
• Customization of documentation through the addition of your own text and graphics (e.g., your organization's logo)
• Compatibility with a variety of various graphics, spreadsheets, word processing applications
• Option to export in DXT format (for inclusion in AutoCAD) and WMF format

Operations-Related Features and Associated Benefits

• Detailed modeling using unit procedures and operations - allowing for a clear and accurate representation of the plant equipment and processes
• Flexible operation models such as batch, semi-batch, and continuous - provide the ability to switch between operating models
• Scheduling of batch operations optimizes the use of materials, equipment, resources, and labor - saves both operating time and cost of operation
• The visual representation of the entire process, coupled with the simulation capabilities - facilitates technology transfer and process fitting during the transition from development to manufacturing
• Throughput analysis allows for the identification of critical bottlenecks in the process - helps analyze and find solutions for increasing productivity and quality while decreasing costs of the production process
• Outputs include:
  • Operations Gantt charts (graphic schedules - see sample capture) can be exported directly to Microsoft Project
  • Equipment Occupancy charts
  • Resource Demand, Labor Demand
  • Resource Inventory

SuperPro^® Contributes to Operations Training Effectiveness

• Entire process is represented on computer screen, thus initial training of personnel can occur before stepping foot in the plant
• Read-only versions of process can be generated and displayed on any computer, thus users are able to browse at their own pace, view specific parameters, flow rates, volumes, temperatures, etc. at their comfort level
• Excellent for brief overviews of complicated systems
• Training tool that bridges the gap between blueprints and actual equipment
• Low cost opportunity to generate a clear, visual representation of a given process that also contains readily available process parameters and details
• Well-trained and knowledgeable employees reduce friction that often occurs between production and maintenance staff

Quality Assurance-Related Features and Associated Benefits

• Waste stream characterization
  • Enables easy classification of each stream in the flowsheet
  • Allows product stream to be visualized
  • Potential contamination areas to be pinpointed
• Identification of Critical Control Points and Standard Operating Procedures (SOPs)
  • Can be integrated with existing HACCP or HAZOP as a precursor to implementing HACCP or HAZOP at your facility
  • Use as another tool for your TQM (Total Quality management) programs
• Performs primary Volatile Organic Compound (VOC) Emissions calculations from batch manufacturing facilities and secondary emission calculations from end-of-pipe treatment processes - enables the user to specify and track emissions of particulate and other related compounds for which no mathematical models are available
• Environmental impact assessment with specification of Actual and Permit Allowable flow rates of various pollutant categories such as total particulate, total VOC, acid gases, extremely toxic gases, carbon monoxide, etc.
• Detailed reports and charts for the above outputs - allows for a detailed evaluation of the process' emissions and the allowable limits
• Air pollution control allows the QA staff to:
  • Review designs for validation purposes
  • View set points and targets for operational and performance qualifications
• Training tool - assists in providing a visual representation as well as process details in the training of employees

Financial Analysis or Cost Reduction-Related Features and Associated Benefits

• Thorough process economics which facilitates estimation of capital and operating costs
• Equipment sizing and costing, as well as preliminary economic evaluation and profitability analysis of manufacturing and environmental processes
• Resource (utilities, raw materials, and labor) tracking as a function of time to pinpoint areas for improvement or better management of resources to maximize profits
• Cost-of-goods analysis and total project economic evaluation available to generate quick estimates of possible future expansions, process alternatives or the profitability of new ventures
• Ability to experiment with alternative process setups and operating conditions has the potential of reducing the costly and time-consuming laboratory and pilot plant efforts
• Customized reports allow the user to show a simplified or detailed economic analysis
• Financial Reports:
  • Economic Evaluation Report: Itemized equipment FOB cost, Annual operating cost summary, Profitability analysis (including net profit, gross profit, ROI, payback time, etc), Utility requirements, and more
  • Itemized Cost Report: View a cost breakdown by different sections and subsections of the design case in terms of raw materials, labor dependent, equipment dependent, consumables, waste treatment/disposal, utilities
  • Cash Flow Analysis Report: cash flow breakdown for every year the plant is in operation, calculates net present value and IRR, loan information, breakdown of capital outlay, etc.
• Economic information generated by the reports allows cross-comparison with other management resource planning tools

Research and Development-Related Features and Associates Benefits

• Simulation tool where process parameters related to a new product or new process are entered in, and the first design stages of the new process are performed in a visually-effective flowsheet
• Provides material and energy balances of integrated processes, thus various modeling scenarios may be evaluated quickly and cost-effectively
• Calculations such as equipment sizing, throughput analyses and economic evaluations are performed by the program, thus preliminary information is easily attainable to determine how cost-effective the new venture is for the company
• Furthermore, process-related capital and operating costs, ROI, payback time, etc. are all generated in detailed reports
• Raw ingredient requirements, utility requirements, manpower and waste generation from the new process are all displayed graphically, thus enabling preliminary decision making and scheduling

SuperPro^® Contributes to Training Effectiveness in R&D Settings

• R&D personnel need to be familiar with the production process in order to have a better understanding of processing limitations, thus using SuperPro^® as an independent learning tool for your employees will result in better solutions and will contribute to the company's bottom line profit
• Combine valuable knowledge gathered from various departments in one centralized tool that is always available and offers knowledge-transfer on all levels, from a basic visual representation of the process to details such as the sequence of operations that occur in each unit procedure or piece of equipment, specific flow rates, temperatures, pressures, etc.
• Access to in-depth process knowledge is available before ever stepping foot in the production area
• Bridge-building tool that encourages information-sharing between Operations, Engineering, Quality Assurance and R & D
• Effective tool to use during presentations or meetings with upper management, because the proposed new product or process may be easily drawn, visualized and explained

Contact Us for more information about SchedulePro^® Designer.