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How It Works2022-07-19T15:13:53-05:00

Systems As Building Blocks

When you walk through a manufacturing site you see many different Systems. The further you walk, the more Systems you will see. It is these Systems and their interactions that are the building blocks that make each site unique.

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Process Efficiency Toolbox™ guides you through a technical review of your systems to identify efficiency opportunities that are specific to your manufacturing processes.

3 Software Products

  • Process Optimization XPS™
  • Sustainable Manufacturing XPS™
  • Troubleshooting XPS™

200+ Systems

You can license any number of these systems for any of our software products to create a customized solution to meet your goals and budget.

Return on Investment

Our products are designed to deliver value.  You can get started very inexpensively with 1 software product and 1 system. After you see the results, you can add more systems as needed.  Low Risk, High Reward.

Powerful Software Tools for Process Improvement

The Process Efficiency Toolbox™ is Powerful and Easy to Use

Answer Questions

Simply answer specific system questions with multiple choice answers.

Software Generates Ideas

Process efficiency improvement ideas are generated based on artificial intelligence logic and expert system analysis.

Pick Your Target

You determine which ideas make sense to pursue based on your goals and budget.

What Type of Questions are Asked?

No privacy, proprietary or financial data needed to answer questions. Some example questions are shown below to illustrate the data entered.

SystemCategoryQuestion
Air CompressorOptimizationIs there a secondary storage receiver? (Yes,No)
BoilerEnergy SavingsDoes the deaerator have a manual vent control? (Yes,No)
Distillation ColumnOptimizationIs the reboiler return line located at least 12 inches above the column’s high liquid level? (Yes,No)
PumpTroubleshootingDoes the centrifugal pump intermittently lose suction when it rains? (Yes,No)
Reverse OsmosisCapacity IncreaseIs the actual permeate conductivity significantly lower than the required permeate conductivity? (Yes,No)
Spray BoothEmissions ReductionHow frequently is the air flow balanced in the spray booth? (Never,Daily,Weekly,Monthly,Yearly,Other)
Steam DistributionQualityAre the steam traps in the steam mains spaced further than 200 feet apart? (Yes,No)

For the more difficult questions, the software provides detailed information.

For example in the Cooling Tower system with the Water Usage Reduction category the question: Are cycles of concentration tracked or reported on a regular basis? (Yes,No)

It also contains helpful information to assist the user in answering the questions, such as: Cycle of concentration is the ratio of total dissolved solids in the blowdown water divided by the total dissolved solids of the make-up water.

Steel Pipeline Equipment

Key Performance Indicators

Process Efficiency Toolbox™ has built in measurement and tracking capability for 25 key performance indicator metrics.

KPI Metrics
KPI Metrics
Technical Training

Technical Training

Process Efficiency Toolbox™ is a training tool for your technical employees. They will gain technical knowledge to make systems more efficient, reducing costs and wasted material and energy.

Technical Training

Deployment Options

Process Efficiency Toolbox™ is easy to use, and you decide the best method to deploy it at your company. We have listed three options for you to consider.

Engineers and Technical Employees

Use your own team of existing employees.

Compare Deployment Options

Co-op and Intern Students

Have co-op or intern students gather the data.

Professional Engineering Services

Use PROCOR engineers to implement.

Frequently Asked Questions

How is the Process Efficiency Toolbox™ different from idea management software?2022-07-18T16:28:52-05:00

Idea management software comes with no ideas.  Typically, ideas are added by crowdsourcing and the ideas are selected by a search or a scoring system.  Scoring can often be quite misleading. If everybody scores the idea, then the score tends to become diluted. If an idea is scored by a small group, then the score can easily be biased.

The Process Efficiency Toolbox comes already populated with process improvement ideas, questions and rule logic.  An idea is only presented when the artificial intelligence believes it is applicable.   For example, assume a corporation has 20 plants and has added a great reverse osmosis idea. Only the users who answer questions in a specific way will see the new idea. If 12 plants don’t have a reverse osmosis system, then they will never see the idea because it doesn’t apply to them. If 4 more plants are utilizing a sodium bisulfate pre-treatment, they will never see the idea because it doesn’t apply. If 2 more plants are using well water as the feedwater, they will never see the idea because it doesn’t apply. Only 2 plants will ever see the idea because it only applies to their plants.

Why do I need any more ideas when I already have enough ideas?2020-02-13T09:06:04-05:00

Our ideas are generated by a logic rule based approach.  This approach is thorough to prevent any missed opportunities.  Our ideas are non-biased, whereas many existing ideas are based on what is already familiar.   It is often true that “you can’t see the forest through the trees” meaning focusing on small ideas and missing the big opportunities.

How can individual systems model my production process?2022-03-31T12:22:08-05:00

Manufacturing processes are composed of unique combinations of individual interacting systems.  Our systems are the building blocks for a unique process.  The interactions between systems are addressed in the questions asked.  Questions can function to weave systems together.  This allows each system relationship to be handled uniquely.  If another system is present, then more detailed questions will be asked based on answers provided.  This will very quickly lead to very specific system relationship questions being asked.

I don’t understand how a generic system name can relate to my specific system?2022-03-31T12:21:02-05:00

The first few questions asked will typically drill down to your very specific system.  For example, we have a “pump” system rather than the following systems:

  • pumps, centrifugal
  • pumps, gear
  • pumps, magnetic drive
  • pumps, air diaphragm
  • pumps, peristaltic
  • pumps, electric
  • pumps, water

The first few questions asked in the pump system will narrow down your specific pump to the degree required to provide process improvement ideas.  The questions also allow for helping a user even if pieces of information are unknown.

Another reason for not specifically naming all subsystems is that this would have created many hundreds more systems.  This would have made the tool harder to use.

Process Efficiency Toolbox™

Making it easy for companies to improve process efficiency and reduce costs

Get Started

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