Projects with OKAY
Whatever the size of your project, OKAY is here to help.
From single machines to large waste processing plants, we are here to work with you, develop your project and deliver your goals.
As a technology leader in recycling and materials handling, we design and build high performance recycling equipment to help processors become ever more efficient.
Our core expertise is converting waste into value for our customers and streamlining their operations. This is how we do it.
Project Management
All OKAY projects are appointed one Project Manager and one Project Engineer. This ensures all all elements are fully covered on a project: customer care, safety, responsibility matrix, commercials, project programme, project budget and engineering.
The PM is charged with the overall success of the project for both the customer and OKAY. The PM works to achieve the project goals for both parties and to drive the project forwards, keeping all stakeholders informed of their duties/tasks in order to keep the project running to time.
The PE is the project technical lead and retains responsibility throughout for the successful design, build and operation of the new equipment.
Project Goal
The first step in a project is to set its goal. Even ahead of agreeing a design concept, we ascertain what the customer is truly wanting to achieve from the project. That becomes the guiding focus of the project and we build everything around that.
Material Flow
Once we know what the customer is wanting to achieve, we can start to build the project in all areas.
The first area is the flow: we put together a flow to show the material input and the kit needed to deliver the required outputs. We agree this with the customer who may have certain preferences on machine types, control software and automation levels.
Site Review
When the flow is agreed, we review the area the customer has made available for the equipment to ensure the space is sufficient to achieve the customer’s goals.
We also review all the new plant interfaces that will be needed at site (civil, electrical, controls, alarms etc) and agree the full list of enabling works with the customer and who will do each item.
Design
We then put together a 3D model of the new kit in the flow as well as the customer’s building/area. We value engineer this ourselves internally and then present it to the customer for their input. It usually takes a few iterations to match the layout exactly to customer’s operations and to condense the new plant footprint to leave as much operational space as possible.
For complex, bespoke engineering, the first design is rarely the best. The best layouts always come from sharing our plant building experience with customers while they share their operational information, future plants and specific market demands with us. Once we match those inputs, the design is unique and truly works for that customer. This is the point of design freeze. From this point, a customer feels comfortable placing an order with us.
Hazop/ALM
When the design is agreed, we then bring in the customer maintenance team to get their input on what will work best for access to the plant and its machines and controls. We use our safety and engineering knowledge to compliment their requirements across the plant to ensure a future operation that work best for them.
Detailed Design
Once we achieve design freeze after the Hazop/ALM meeting, we can finalise specifications and start to place orders for long lead items and engineer the system in detail.
At this point, we work with the third parties to integrate their models exactly with our own and we apply all our years of materials handling experience to ensure continuous flow at every interface point. We also design access platforms, standard and bespoke chutes and we begin to release finish designs to the OKAY factory for manufacture.
Controls
As part of the design work for the system, we start to discuss the specific programming functions, reporting and interface that the customer wants from the control system so that too is a match for their future operations. If the project is an upgrade, OKAY will either work with the incumbent electrical/controls supplier or, if access is available, take over the system.
Manufacturing
Whilst concept, design, safety and controls are the foundation stones of a new plant, there is nothing quite like seeing the machines and structures come to life in the shop. As a British manufacturer, OKAY builds all of its machines here in the UK and we welcome customers to the factory to see their kit in build. We also FAT test with customers in person, or via video, and this gives commercial customer colleagues huge confidence before the despatch payment. With all our kit being made in Britain, our factory not only ensures a minimised carbon footprint and zero currency risk for UK customers, but no border delays or paperwork headaches too.
The greatest element for us about being the manufacturer is the quality control it ensures in our products from start to finish.
Installation
It may seem counterintuitive but installation planning begins almost immediately on a project. This is not only so we design and build the equipment in the right order for the site install team but so we minimise business disruption for the customer.
Installation is a huge part of project management and we have a dedicated installation team to pull all site activities into one programme early in the project; then they keep focus on the site works within the project and later coordinate events at site in order to control safety and deliver the installation timeline.
Commissioning
Split into cold commissioning (no materials) and warm commissioning (with materials), our handover process to customers is the most important phase. This is the moment of lift. Everything they and we have been working on over the project aligns at this stage when the incoming materials are processed successfully for the first time.
Training
Over the later stages of commissioning, we train all customer safe to operate the new equipment safely and efficiently. Classroom sessions blend with on-the-job training and all successful attendees receive a certificate to show a safe working knowledge of the new plant.
Handover Process
Initial Handover: When the customer takes over the operation of the plant, it is deemed Initial Handover.
Snagging: At this point, any outstanding snags are agreed and given action dates.
Testing: Sometimes customers have specific tests that they want the plant to be able demonstrate it can pass. Protocols for this are agreed in advance with the customer and data and material samples are recorded to prove the success of the tests.
Final Handover: When the plant is running successfully, all snags have been resolved and the customer is happy, final handover aka final acceptance has been achieved.
Aftersales Care
At this point, OKAY’s Aftersales department takes over the care of the plant with the customer to arrange service visits, spare parts, top-up training, any warranty care issues and day-to-day advice.