Industrial engineering project phases, let’s get to know them

What is the development of an industrial engineering project?

Let’s start by explaining what the development of an industrial engineering project consists of. We first need to know that this is the process where we can define and measure its technical and economic viability. Next, we should understand the importance of defining each one of the phases of an industrial engineering project, to generate a framework, independent of the type of methodology used, the tools, resources, and other aspects necessary for its realization.

Furthermore, it is the basis for performing an industrial turnkey project, or either one or some fraction of the entire execution or operation. For this reason, we will stop to explain each one of the phases of an industrial engineering project, through the levels of development such as:

• Basic engineering
• Detailed engineering
• As-Built Engineering

Later we will talk about them, now we will focus on knowing the main phases of an industrial engineering project, after that, the most common methodological frameworks to be applied.

What are the phases of an industrial engineering project?

Each process requires certain steps or stages to be able to maintain adequate control, to avoid losing resources during execution or to always have the objectives monitored, among other benefits. Let’s start reviewing them.

Identification

Before starting, it is always essential to locate the objectives, the scope, and, of course, the problem that you want to solve. In this first stage, any decision must be made to manage resources, considering the project viability correctly.

Besides that, as the business plan is considered, which includes documentation to evaluate the economic aspects, the feasibility study, in which an analysis of all available resources, conditions, scope, and factors that could contribute to its success or failure are carried out.

Planning

In the second stage, once we have proven that the industrial project is viable and that the industrial project is viable and that we know everything that will be needed, it is time to start planning.

At this stage, the legal and safety conditions are considered, as well as the specific requirements of the clients and the following are determined, plans, distribution, and tasks assignment, progress schedules and budgets.

For example, at this stage, we need to know the plan’s needs to propose delivery times, procedures to be carried out and if necessary, carry out supplier management, integration, and maintenance tasks.

Execution

This is the construction and start-up of all the activities related to the project after the planning. Even so, it is necessary that, throughout this stage, controls can be carried out to identify deviations or losses. Of course, it is also possible to carry out simulations of industrial processes, in this way risks can be prevented in the real-world during execution.

Follow-up

This is a stage that is present through the entire process, since it is essential to avoid errors that translate into losses. For successful monitoring, it is recommended that opportunity areas to be identified, continuous project review, comparing results with original plans, providing ongoing information to the client, and performance evaluation.

Closing

This is a complete delivery of documentation to the client, in which the evaluations and records carried out throughout the project are delivered so that you can know precisely what was done, how it was done, and how it can be improved in the future. During this stage, compliance with the initial specifications is established.

Methodology for industrial engineering projects

As we anticipated, in procedure within the industry, there are different methods or models that allow us to dissect, understand and adapt the process to the sector. Next, we will talk about two classes of models from which the phases of an industrial engineering project are derived.

Broadly, we will introduce two types of methodologies: Agile and Waterfall.

Agile methodology

The Agile methodology is recent since it emerged in 2001 through a manifest sign by 17 programmers committed to their clients and work. This method began as part of the added-value software development principles. However, it was taking shape towards other, more general industries. This method works with the engineering project phases.

So, the appropriation of this methodology for project development and management has remained current due to its versatility. But what does it consist of? Well, this is a methodological framework with the particularity of being repetitive and, above all, its efforts are focused on human capital.

Repetitively, each phase in this industrial engineering project is reviewed continuously and constantly. These are called sprints and the main idea is that each one has a defined duration with various activities or actions, but at the end of this stage, a report is made which the client reviews. Once the feedback is obtained, it is possible to structure and prioritize the next sprint; repeatedly until the end of the project.

Here, unlike what we will see in comparison to the Waterfall methodology is that, as the name implies, it is agile, dynamic, and, in a certain way, cyclical. The opposite of what happens with the Waterfall method, since it has a staggered structure, as we will see in the next section.

For this reason, it is a participatory model where the client takes an active role in the decision-making process during the project and at the end of it. It should be clarified that there are advantages and disadvantages, as we will now disclose.

Agile methodology advantages:

• Belonging: The sense of belonging with the client is strengthened.
• Opportunities recognition: The client can identify opportunities, and even make project decisions early.
• Better management: Provides tools to empower work teams in project management.
• Trust: Generates high customer satisfaction, an issue representing trust and loyalty for the company that manages the project.

Agile methodology disadvantages:

• Lack of interest or time: Although this method encourages customer participation, it can also be a negative because sometimes the person requesting it, needs more time or interest to interact with the work.
• Additional sprints: As we mentioned earlier, it is done based on modules called sprints. However, on many occasions the deadlines agreed upon at the beginning are not met and, with this, there are in addition extra sprints to complete the previous ones. This is translated into higher costs, longer lead times, and prior agreement modifications throughout the phases of an industrial engineering project.
• Lack of experience equals lack of quality: If you don’t know how to carry out the initial planning and design, these gaps will appear throughout the project and, at the same time, denote low quality.

Waterfall methodology

On the other hand, the Waterfall or “cascade” methodology represents a linear model in which the phases of an industrial production project are carried out one after the other. In such a way, they follow that downward effect, hence the origin of their name. In addition, this structure has been in force for more than half a century. However, it is less flexible in relation to Agile methodology, due to its order; in general, it is the one that sets the pace of the project.

Thus, we carry out the phases one by one until we conclude; that is, we must develop a schedule and initial plan. However, as with Agile, the Waterfall methodology has advantages and disadvantages. Next, we will list a few and then make a comparison between methods.

Waterfall methodology advantages:

• Project identification: By having a more orderly and rigid structure, clients know the entire process (through the phases of an industrial engineering project, such as planning and design).
• Fixed costs: When we start the project with the Waterfall methodology, the client knows the costs, which is why modifications during the process become difficult.
• Non-centralized human capital: In this type of project, the teams also carry out the specific activities of their position.
• Simplicity in planning and design: The defined work plan is delivered to the client from the beginning. This allows greater control of all aspects and simplifies all phases of an industrial engineering project, including planning and design.

Waterfall methodology disadvantages:

• Not very functional in long-term industrial engineering projects: Due to its strict nature, it is only partially suitable for long-term work.
• Costly and difficult to correct errors: In this case, one of the most serious difficulties is that if we do a good planning and design, in the long run, this will be reflected in the work plan, where errors are difficult to solve, and they may end up with a price above the initial proposal.
• Low customer participation: As there is no greater link on the part of the customer, other than contacting the service, there is little involvement in industrial engineering projects and, ultimately, this can impact on the main approaches.

Comparison between Agile vs Waterfall methods

According to the above, both methodologies have their pros and cons. However, none is better or worse than the other. Here, we must consider what our client is looking for, the times, the costs, as well as the personalization and involvement of the client in the project to define the framework with which we will work in the management.

As we can see in the case of the Agile methodology, flexibility, and adaptation based on the client’s needs predominate. On the other hand, while with the Waterfall methodology we obtain greater organization before, during and after the project is carried out by the above but transmitting a technical interpretation to the solutions that require.

Thus, we can consider two ways to carry out the projects based on different methodologies. We will be able to go on to identify each of the phases of an industrial engineering project with reference to the implementation levels and engineering execution.

Engineering implementation and execution

Throughout the text, we have mentioned what industrial production projects are and various methodologies for their implementation. Now, we’ll be introducing the phases of an industrial production project based on the implementation and execution of engineering. Let’s start with basic engineering.

What’s basic engineering?

We always start with basic engineering when we carry out a turnkey project. With this, we refer to preparation, design and planning of the DTI or Piping and Installation Diagrams, also known as P&ID or Piping and instrumentation diagram, where the network and orientation studies that will serve as starting point are drawn and outlined of the entire industrial engineering project to carry out processes and subsequent ones.

What’s detailed engineering?

Throughout detailed engineering, we make integration improvements and integrations that allow the correct execution of the project. Here, deliverable products, such as plans, calculations, and other technical specifications have been generated that complement the information already collected in the DTI.

What’s As-Built engineering?

Finally, we will talk about As-Built engineering, which constitutes a fundamental part since it corresponds to the definitive stage where all the changes and modifications of the final project are integrated as a point of reference on the final project decisions.

Now, considering the methodology and phases of an industrial engineering project according to the engineering levels, your processes will be more agile. In addition, you will be able to immediately recognize your client’s need to implement the model that best suits their requirements.

Do you need more information about the solutions we offer you in Autmix Group for turnkey projects? Contact us.