Construct a site layout diagram (include an indication of the main plant areas, the store(s) and tool store(s) locations and the workshops, with a simple coding to identify the location of the tradegroups). See Figure 5-1 as an example.

Establish size of site.

• Capital cost of plant?

• Age of plant?

• Age of process technology?

• Is it multi-product?

Construct a process flow diagram partitioned at unit (e.g., mixer or compressor) level. See Figures 5-2 and 5-5 as an example.

• This may be hierarchical.

• Indicate flow direction, capacities, all storage points and capacities.

• Indicate stand-by units and/or excess capacity.

• Identify bottle-necks.

Identify total number of employees, and of maintenance employees.

Understand the operating policy for the plant.

• Identify operating pattern (e.g., continuous, 5 3 shifts, etc.)

• Understand the relationship between the plant and its market (is it steady or dynamic).

• How is this affected by final stage storage?

Understand the operating policy for the plant units taking into consideration the level of redundancy (e.g., where there are three units, how are they operated if (a) all three are required, or (b) only two out of three are required, etc.?) Identify and record operating procedures for the main units.

Understand how other production factors affect the plant operating pattern. For example:

• Catalyst changes.

• Raw material supply.

• Availability of services.

• Cleaning.

• Manpower...