When you operate a production plant, it is a good idea to produce a document containing a structured description of how the plant can be developed, usually from a production technology perspective. This document thus becomes a technical development plan. This type of plan can go by a number of different names, for example Master Plan, Long-term Development Plan (LDP) or Business Continuity Plan (BCP). Here we have chosen to refer to it as a Master Plan.

A Master Plan can be used to create supporting documentation for the development of the plant with reduced production costs as a goal, map investment requirements, identify technical business risks or create a picture of the efficiency improvement potential at the production plant. A Master Plan functions as decision-support documentation for overall structural decisions that impact the total production capacity in a business.

The plan can also advantageously be used as an overall approach to energy efficiency measures and as a useful tool in the work involving the identification of fire and explosionrisks, for example in  connection with a future expansion of the plant.

Areas of application for a Master Plan:

  • Defining planning assumptions, in other words, the planning and design parameters needed in a change/expansion process.
  • Generating a plan that illustrates the long-term physical location of the plant’s main functions, such as production processes, internal logistics, warehousing, energy supply, maintenance, administration, etc.
  • Describing the main configuration of all systems, such as production, packaging, automation, electrical systems and mechanical tools.
  • Illustrating how the expansion of the current plant can take place in phases, including the possible redevelopment of the process.
  • Generating a budget that shows the capital cost (CAPEX) associated with each phase, as well as how the production cost (OPEX) will be affected by the phase.

The Master Plan is not normally based on a calendar year, but rather on the production capacity per year, during a month and a week.

Would you like to know more about how the team at Qestio can help you analyse the potential savings in your production plant and support you in the implementation of necessary changes? Contact us!