+Completed Projects

Engineering Excellence

Conceptual Retrofit Project in phases of the pesticide production building with a study of production capacity.

Detailed projects for retrofitting and improving production and utilities areas.

Detailed projects for retrofitting and improving production and utilities areas.

Conceptual Master Plan for the new Production Site.

Conceptual project to expand the small volume sterile production line.

Conceptual Master Plan with Capacity Study and Detailed Design.

Detailed Design of the Butantan Institute's NB3 Laboratory.

Detailed project to expand Insocaps production.

Conceptual and basic design for the new supplement production unit.

Conceptual Master Plan.

Conceptual Project with study of Production Capacity and Process for New Expansions.

Conceptual project to improve the flow and environmental classification of cosmetics production areas.

Case

Among our cases, we highlight the Aché Group's Melcon Project, where we applied all our work modules from the project's life cycle, meeting all the requirements, deadlines, budgets and GMP certification for the hormone drug production plant that needed to be refurbished and extended while the building was in operation.

Contextualization

The improvement needs of Melcon do Brasil's hormonal solids production plant were determined by correcting the flow of people, materials, and waste, improving GMP conditions for manufacturing and analyzing medicines, and increasing production capacity.

How it was done

The factory remodeling project began with a kick-off meeting and the presentation of the Project Opening Statement, which aimed to define the strategy and execution plan for the expansion/adaptation of the Melcon laboratory production unit. In line with market growth and regulatory demands, they ensured a precise and planned investment.

Após a definição da estratégia e o plano de execução conforme os passos a seguir:

1. Industrial Capacity and Strategy Analysis

The manufacturing growth strategy was aligned with market and regulatory demands, based on industrial sizing methodology and tools, determining the headcount and resources needed for implementation in accordance with the needs throughout the growth plan.

2. Conceptual Design

Based on the industrial strategy aligned with regulatory requirements for improving the flow of people, materials, and waste, the layout was developed considering the following conceptual pillars:

• Utilization of the current structure

• Operational fluidity

• Lower occupancy (built area)

• Feasibility of phasing the work

In addition to minimizing project costs, the implementation plan sought to optimize the phasing of disbursements in order to ensure cash flow with minimal impact on the company.

The administrative areas and the physical/chemical and microbiological laboratories were studied, and improvements were implemented based on the new layout proposal.

The plant protocol was approved by the regulatory agency ANVISA, providing technical support for the project and clearing it for the next phase.

3. Projetos Detalhado

Stage where the project was detailed with the preparation of specifications, list of materials, construction and installation reports, for future purchases of materials and equipment, and hiring of specialized labor.

4. Capex Management

With the completion of the detailed designs, competitive bidding notices were prepared for the procurement of materials/equipment and hiring of labor (Civil, HVAC, Clean Room, Electrical, Mechanical Utilities (Clean and Black Utilities)). All bids were technically equalized and approved for contractor mobilization and commencement of work.

During the execution of the work, supervision and contract management were carried out based on the planning and executive projects to ensure delivery of the correct scope within the expected cost and quality. We used our SGP AuBlack model management tools with physical progress curve controls, measurements, and financial control reported weekly to all project stakeholders.