We identified a need for an engineering, procurement and construction (EPC) firm to shift old-style engineering procedures for relief calculations to new, more accurate approaches using transient analysis. Because the prevalent methodologies were perceived as conservative if inaccurate, they were widely accepted by the industry which viewed transient analysis as an overly complex, costly and “fancy” solution. All these perceptions were inaccurate.
We identified the root cause of the problem as a combination of work-process deficiency for transient analysis and internal cultural beliefs among both the engineering contractor and the client, and set out to change both. First, we established modified work processes borrowed from Agile software development methodologies to greatly reduce complexity and time required for performing transient analysis. The modified processes achieved cost efficiencies that outperformed less accurate non-transient based calculations.
We then embarked on finding champions within the engineering firm to support the new direction, identifying highly analytical and open minded staff as the best candidates. Four champions were selected and we worked closely with them to provide simple solutions to complex client cases where resulting cost savings were substantial.
With the support of the champions, we presented one of the solutions free of charge to the client, who readily agreed to switch all their calculations to transient analysis. As a team we applied the new methodologies to the entire plant, garnering cost savings that far exceeded the cost of the calculations. Additionally, the calculation procedures of the contractor were amended to include the new calculation methodologies.
Overall the changes in work processes and culture resulted in significant savings for a large number of the engineering firm’s clients. Improvements in safety due to the use of more accurate calculations additionally provided a significant competitive advantage for the engineering firm, which maintained a healthy backlog of projects even during industry downturns. The project and related papers we published on the topic triggered the interest of multiple young engineers to learn the new methodologies and upgrade their skills, sparking creativity and a culture of learning.
We identified the root cause of the problem as a combination of work-process deficiency for transient analysis and internal cultural beliefs among both the engineering contractor and the client, and set out to change both. First, we established modified work processes borrowed from Agile software development methodologies to greatly reduce complexity and time required for performing transient analysis. The modified processes achieved cost efficiencies that outperformed less accurate non-transient based calculations.
We then embarked on finding champions within the engineering firm to support the new direction, identifying highly analytical and open minded staff as the best candidates. Four champions were selected and we worked closely with them to provide simple solutions to complex client cases where resulting cost savings were substantial.
With the support of the champions, we presented one of the solutions free of charge to the client, who readily agreed to switch all their calculations to transient analysis. As a team we applied the new methodologies to the entire plant, garnering cost savings that far exceeded the cost of the calculations. Additionally, the calculation procedures of the contractor were amended to include the new calculation methodologies.
Overall the changes in work processes and culture resulted in significant savings for a large number of the engineering firm’s clients. Improvements in safety due to the use of more accurate calculations additionally provided a significant competitive advantage for the engineering firm, which maintained a healthy backlog of projects even during industry downturns. The project and related papers we published on the topic triggered the interest of multiple young engineers to learn the new methodologies and upgrade their skills, sparking creativity and a culture of learning.