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Special Fabrications Solve Unique Design And Processing Requirements, But Selection Of Supplier Is Critical To Success
by Dan Mathien, Sales Manager, Swagelok Biopharm Services Company
More manufacturers and system fabricators in the biopharmaceutical industries
are recognizing the value of using special fabrications for solutions to unique
assembly requirements for their processing systems. Although special fabrications
are not needed for every job, the reality is that many projects will require the
use of more than one-size-fits-all products or complex configurations of fluid
components at some point during the construction phase. Oftentimes, special fabrications
are simply a more cost-effective solution for the process application. If incorporated
into the design of a system, special fabrications can help simplify that design,
reduce the system footprint, and minimize field welding and installation costs.
Other times, the need for the special fabrication occurs when 90 percent of the
construction job is complete and the demand to remain on schedule arguably is
at its highest.
With that in mind, special fabrications play an important role as “lifesavers,” enabling fabricators or manufacturers to meet critical construction deadlines and move projects forward with minimal or no delays. Essentially, special fabrications are considered to be any product or fluid component configuration that is configured to order or designed for a specific application. More often than not, they become necessary because of changes in design that come to light only during the construction phase. Special fabrications historically can range from simple alterations in dimensions for individual fittings to the production of an entire skid, as well as the engineering, design, and development of a complex configuration of valves, manifolds, tees, and other components.
Case Studies
For example, one manufacturer required a 3-liter cooling chamber to feed water
to mechanical seals in a pumping system. The chamber required a ½
Figure 1: This 3-liter cooling chamber
was specially fabricated to feed water to mechanical seals in a pumping
system. The chamber was burst tested to 200 psi for one minute at 150o F.
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inches coil, pressure switch, ball valves, sight glasses, liquid level probe and
a fractional pressure gauge. The special fabricator supplier took a comprehensive
look at what was necessary to make the chamber functional and reliable and designed
a solution. The installation was successful and the custom fabricated chamber
was burst tested to 200 psi for one minute at 150° F (Figure 1).
In another case, a manufacturer required an inline strainer similar to a supplier’s
stock item but had limited space for installation. The supplier designed a custom
strainer to fit the space required with shortened back up tubes and a full line
of replacement mesh over screens. The special fabricated part worked out so
well that the manufacturer has placed more than 80 orders for the same custom
part since the initial installation.
In both cases mentioned above, the special fabrication process was successful because the expert supplier designed custom quality parts with a fast turnaround time. When evaluating special fabrication suppliers, it is important to evaluate each company’s track record to raise the odds for project success.
Selecting The Right Supplier Is Critical
Because the need for special fabrications tends to occur late in the construction phase, many fabricators and manufacturers will have a tendency to select a supplier solely on the basis of whether it can meet their construction deadlines. While it is imperative that a special fabrication supplier comply with the time constraints, a host of other criteria is equally important when it comes to deciding which supplier is the right one for the job. Making the wrong choice can lead to major consequences and a myriad of problems, including quality issues, lengthy site delays and downtime, and validation problems. Steps, however, can be taken to ensure the selection of a special fabricator that meets a project’s specific needs while maximizing productivity and efficiency, without compromising system quality.
When selecting a special fabrications supplier, recognize that price is not the main determinant of whether the supplier can provide the best solution for an application. The first step in selecting a supplier actually should involve an evaluation of the breadth of services that are offered. Some suppliers offer limited services, while others provide comprehensive and value- added services that help ensure reliability, quality and long-term performance.
The challenge is to find a supplier that is oriented toward providing solutions and can provide a level of quality that will be consistent with the installed products. For example, a fabricator may want a quick turnaround on a dimensional change to a fitting to complete a phase of the project. But a supplier who is solutions oriented and offers a wide range of services may be able to offer a more cost-effective solution that can be built—to your design—within those same time constraints. The result may be a smaller dimensional footprint or lower field welding costs, for example.
Consider Outsourcing vs. In-House Issues
Some suppliers also are structured in a manner that enables them to respond
quickly with a focus on quality and performance. One top-tier supplier, for
example, has dedicated a group of its engineering, design and manufacturing
staff to special fabrications. On a daily basis, the staff is working on
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Figures 2 and 3: Special fabrications
are considered to be any product or fluid component configuration that is
configured to order or designed for a specific application.
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special fabrications, from welding, polishing and machining materials to costing
out products and developing CAD drawings. Some suppliers also put a premium
on reliability, employing procedures and manufacturing processes that enable
them to provide the same level of quality for the special fabrication as they
do for standard factory components.
Further consideration should be given to how many of the supplier services are
outsourced versus maintained in-house. For example, some suppliers don’t have
the capability to complete electropolishing while others have dedicated welders
and polishers just for special fabrication jobs. The more control a supplier
has over the special fabrication process, the better ability it has to reduce
errors, maintain quality, and avoid time delays.
By thoroughly assessing a special fabrication supplier’s capabilities, a manufacturer
or fabricator is better positioned to make the best choice and get the most
from a special fabrication. Here are some capabilities to consider:
• Turnaround time – A quick turnaround time for completion of a special
fabrication is typically the most critical element, especially when attaching
a cost to manufacturing time lost. In the biopharmaceutical industry, a manufacturer
can lose millions if a process line is down. It is important to determine a
supplier’s turnaround time for a quote as well as for shipment of the product(s).
Some suppliers ship to a promised date and hold to it as if the special fabrication
is a stock item. Also, some special fabricators are able to provide a drawing
and a quote in four hours and delivery in as short as three days.
• Quality – Some suppliers have all capabilities in-house, enabling them
to maintain stringent quality control, while others need to outsource services.
For example, evaluate whether the special fabricator has in-house capabilities
for completing the electropolishing feature necessary for biopharmaceutical
processing. Also, determine whether the supplier offers a repeatable process
that will provide the same quality standards for a future project. In general,
think long-term for maximum efficiency and cost savings. Labor may be cheaper
in the short-term with a subcontractor, but it can cost more down the road because
of quality issues.
Figure 4: When selecting a special fabricator,
choose a supplier that can deliver a quality product made specifically for
the unique design requirements in a promised delivery timeframe.
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• Validation and third-party inspection – Determine whether the supplier’s
cost includes documentation, weld logs, and inspection. Some suppliers have
special fabrications inspected in accordance with ASME-BPE standards by an independent
third-party inspection company before shipment. This value-added, third-party
inspection service can help end-users reduce time and costs related to on-site
conformance inspection and validation process delays.
• Flexibility – Review how much of the company’s core business is dealing
with special fabrications. In addition, determine if the company has dedicated
resources for special fabrications in design, assembly, welding, and polishing.
Most likely, a supplier with special fabrications expertise will offer a more
efficient and smooth ordering process.
Evaluate if a supplier offers complex technology solutions, and also assess
how rigid a supplier is in its special fabrications offering. For example, if
a
supplier employs a “you dream it; we will build it” attitude, a manufacturer
will not have to reconfigure its design just to make the special fabrication
work.
In conclusion, do homework before and during the selection process of a special
fabricator to avoid downtime, delays and quality issues. By choosing a supplier
that can provide the desired products and service for both the present project
and future needs, maximum time and cost savings can be achieved. Find a supplier
that can deliver a quality product made specifically for the unique design requirements
in a promised delivery timeframe. And, carefully consider flexibility and value-add
resources such as third-party inspection to reduce time and costs related to
on-site conformance inspection.
Pharmaceutical Processing
Advantage Business Media
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