De-Risk Process Changes with Two-Week Pilot Tests
Problem
Fear of unproven modifications prevents process improvements
Solution
Controlled pilot tests validate changes before full implementation
The Challenge
Operations teams are naturally conservative about process changes—for good reason. An untested modification could cause trips, quality issues, or safety concerns. But this conservatism prevents beneficial improvements that could increase production or reduce costs.
How do we test new ideas without risking the facility?
The Pilot Testing Framework
Structured Two-Week Validation:
Phase 1 - Safe Design (2 days):
- Define success criteria and abort conditions
- Identify monitoring requirements
- Plan rollback strategy
Phase 2 - Controlled Test (7-10 days):
- Implement change during stable operations
- Monitor continuously with tightened limits
- Collect data on key performance indicators
Phase 3 - Evaluation (2 days):
- Analyze results vs. baseline
- Calculate economic benefit
- Make go/no-go decision
Examples: Testing new chemical additives, modified operating parameters, or alternative control strategies.
Success Stories
Recent pilot projects:
- Separator chemical optimization: Tested new demulsifier, reduced chemical costs by 40%
- Heat exchanger bypass testing: Validated 15% energy savings before implementing fleet-wide
- Compressor speed optimization: Proved 3% efficiency gain with zero impact on stability
Pilots typically cost $10-20K but validate improvements worth $100K-500K annually.
Low risk. High confidence. Fast results.
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