the cadbury project
DESCRIPTION
This is a project management plan for the reorganisation of chocolate making equipment for a more efficient workflowTRANSCRIPT
Project Management Plan
Chocolate Making Production Lines –Reorganisation
Presented By:Brian Phelan Lucas Costa Mattia Sergi
Leticia Reis CastroNick Hegarty
Project Justification - GoalsRe-develop the chocolate making process in the
Dublin factory to streamline the process and remove excessive conversion costs.
Remove excessive labour costs from the processIntroduce a faster and more controlled processRemove the hazard associated with manual
transfer of chocolate from the Conches to the Storage tanks
Project OverviewRe-develop the chocolate making process in the Dublin factory to streamline the process and remove excessive conversion costs.
Project Justification - Benefits
A reduction in the processing time and the automation of the Conches emptying would allow for a reduction in labour costs and an added benefit of increasing the plant Overall Equipment Effectiveness (OEE).
Other benefits include removing the health and safety hazard associated with the manual transfer of chocolate from the Conches to the storage tanks.
Project - Description
The current liquid chocolate making process utilizes 10 three Tonne Conches.
When the processing time is complete, the chocolate is removed and transported manually via trolley to a pumping station into large storage tanks.
This process is slow, requires significant manual labour and poses a health and safety risk.
The objective is to replace the current three tonne conches with four, six tonne Conches.
Current Layout Schematic
Proposed Layout Schematic
Equipment Photo
Row of five 3 tonne Conches
Equipment Photo
3 Tonne Conche
Equipment Photo
Chocolate Refiner
Equipment Photos
Six Tonne Conche
Initiation Planning Execution Control Close
2.Statement of
Work
3.Project Charter
A.WBS
B.Project
ScheduleC.
Project Budget
D.Project
Quality PlanE.
Comm’sManagement
PlanF.Risk AnalysisG.
HR PlanH.Procurement
Plan
2.Scale Up
Plan
3.Validation
Plan
4.Distribution
Plan
2.Issues and Risk Logs
Pre-Baseline Approval
Baseline Approval
Go-Live Approval
Project Closure
1.Business
Case
Project Justification
1.Project
Management Plan
Containing
1.Change Request
1.Status Reports
1.Project Review
Initiation Planning Execution Control Close
2.Statement of
Work
3.Project Charter
A.WBS
B.Project
ScheduleC.
Project Budget
D.Project
Quality PlanE.
Comm’sManagement
PlanF.Risk AnalysisG.
HR PlanH.Procurement
Plan
2.Scale Up
Plan
3.Validation
Plan
4.Distribution
Plan
2.Issues and Risk Logs
Pre-Baseline Approval
Baseline Approval
Go-Live Approval
Project Closure
1.Business
Case
Project Justification
1.Project
Management Plan
Containing
1.Change Request
1.Status Reports
1.Project Review
Project Framework
Project Scope – In Scope
Installation of three, six tonne capacity chocolate processing Conches and two chocolate crumb Refiners.
Reconfiguration of existing equipment to deliver refined chocolate crumb and cocoa butter to the new Conches location
Any electrical/control software installation workRemoval of all plant and equipment associated
with the ten, three tonnes conches
Project Scope – Out of Scope
Any upgrade to building infrastructure.Overhaul or upgrade of equipment available from
other factoryMachine spare parts.Technical, Process or Maintenance training for
new equipment.
RequirementsReq. No. Requirement Owner Priority
1. Reconfiguration of two Automated Chocolate producing lines utilising equipment made available from another manufacturing plant within Europe
PM H
2. Installation of equipment should conform to all Company Engineering and Health & Safety requirements
PM H
3. Plant should be commissioned following the protocols laid down by R&D department and final product KPA’s should conform to specifications
PE H
4. All equipment shall be controlled by the latest version of Allen Bradley Programmable Logic Controllers (Control Logix)
SE H
5. All Human Machine Interfaces (HMI’s) should be Allen Bradley type Panel View 1200
EE H
6. All Electrical Panels should conform to IP2x rating and shall contain working copies of the wiring diagram
EE H
7. All product contact surfaces shall be constructed of Stainless Steel
ME H
Work Breakdown Structure
N° Task Duration Start Finish Predecessors20 Decommission Production Line 1 and Clean Equipment 5 days 27/03/2014 09:01 03/04/2014 09:01 1721 Remove Conches 1,2,3,4 & 5 5 days 03/04/2014 09:01 10/04/2014 09:01 2022 Install Refiner Number 2 5 days 03/04/2014 09:01 10/04/2014 09:01 2023 Modify Conveying from Refiners to new Conche 1 & 2 5 days 03/04/2014 09:01 10/04/2014 09:01 2024 Install New Conche 1 & 2 5 days 10/04/2014 09:01 17/04/2014 09:01 2125 Install Liquid Chocolate Pipework from Conche 1&2 to Tank 5 days 17/04/2014 09:01 24/04/2014 09:01 2426 Electrical Installation and Testing - Line 1 10 days 24/04/2014 09:01 08/05/2014 09:01 2527 Test and Commission Refiners and Conches 5 days 08/05/2014 09:01 15/05/2014 09:01 2628 Clean Equipment Before Commissioning 5 days 15/05/2014 09:01 22/05/2014 09:01 2729 Ramp up production from New Production Line 1 Layout 10 days 22/05/2014 09:01 05/06/2014 09:01 2830 Milestone 3 05/06/2014 09:01 05/06/2014 09:01 2931 Decommission Production Line 2 and Clean Equipment 5 days 06/06/2014 09:01 13/06/2014 09:01 30;10132 Remove Conches 6,7,8,9 & 10 5 days 13/06/2014 09:01 20/06/2014 09:01 3133 Install Refiner Number 4 5 days 13/06/2014 09:01 20/06/2014 09:01 3134 Modify Conveying from Refiners to new Conche 3 & 4 5 days 13/06/2014 09:01 20/06/2014 09:01 3135 Install New Conche 3 & 4 5 days 20/06/2014 09:01 27/06/2014 09:01 3236 Install Liquid Conveying Pipework from Conche 3&4 to Tank 5 days 27/06/2014 09:01 04/07/2014 09:01 3537 Electrical Installation and Testing - Line 2 10 days 04/07/2014 09:01 18/07/2014 09:01 3638 Test and Commission Refiners and Conches 5 days 18/07/2014 09:01 25/07/2014 09:01 3739 Clean Equipment Before Commissioning 5 days 25/07/2014 09:01 01/08/2014 09:01 3840 Ramp up production from New Production Line 2 Layout 10 days 01/08/2014 09:01 15/08/2014 09:01 3941 Milestone 4 15/08/2014 09:01 18/08/2014 09:01 40
Implementation
Project Schedule
Planning
Reconfiguration of Production Line 1
Commission Production Line 1
Reconfiguration of Production Line 2
Commission Production Line 2
Project Close Out
Control – Weekly Meetings
Gantt Chart plus Critical Path Analysis.
Gantt Chart + Critical Path after Analysis
Project Budget
Budget Overview
Budget Tracking 1Baseline S curve
Budget Tracking 2
Project Quality
The project deliverables are meeting the stated requirements;
The project deliverables are meeting the stakeholders’ expectations;
The project management methodology proposed are being appropriately followed;
For all key decisions there is an appropriate level of sign off;
The scope is clear and has been signed off by all stakeholders;
The project’s objectives have been clearly understood by all project management team.
Project Organisation
RACI Matrix
Tasks Responsible Accountable Consult Inform
Initiation Project Manager Project Manager / Steering
Project Team Project Team
Planning Project Manager Project Manager / Steering
Project Team Project Team
Execution Engineering Functions Project Manager Project Team Project Team
Control Project Manager Project Manager Project Team
Close Out Project Manager Project Manager Project Team
Communications Plan
Deliverable Date / Format Purpose Owner
Status ReportWeekly: Friday @ Close of business dent via e-mail
1. Update steering Committee on status.
2. Risk Management
3. Change requests: Possible budget / resource alteration
4. Issues and resolutions
5. Updates from previous meetings including budget and schedule.
Project Manager
Project Meeting
Weekly: Tuesday 10am-11.30am in main meeting room
1. Review progress against schedule, budget and scope.
2. All relevant parties to provide individual status updates.
3. Change Requests
4. Resolution of outstanding issues.
5. Any other business
Project Manager
Steering Committee
Monday: First Tuesday of the month 8.30am-9.30am in the main meeting room
1. Review progress
2. Decide on change request
3. Escalation point
Project Manager
Risk Matrix
No.
RiskProbability 1 (low) – 4
(high)
Consequence
1 (low) –4 (high)
Risk factorOverall Risk
Rating
1Product from new plant does not conform to KPAs
2 4 8 M
2Scope of the project is not clearly defined (resulting in scope creep)
2 2 4 L
3Supply of chocolate to areas that require it curtailed because only one of two plants availability
3 4 12 H
4Extended commissioning time for new plant configurations
2 4 8 M
5Delays from the removal of existing equipment related to infrastructure
2 4 8 M
6Delays due to Specialist Engineering requirements
3 3 9 M
7Delays due to unforeseen absenteeism and holidays of personal involved in the project
2 3 6 L
8Large Lead times for the procurement of equipment and materials
1 4 4 L
9Budgetary changes due to the requirement for the capital spend being diverted elsewhere
2 3 6 M