30% design review

Keoleian, G. and D. Menerey, Sustainahle Development hy Design Review of Life Cycle Design and Related Approaches , Air [Pg.2154]

To distinguish between a review and an audit, some definitions will be provided. A review is a critical examination or evaluation of any operation, procedure, condition, event, or equipment item. Reviews can take many forms and be identified as project reviews, design reviews, safety reviews, pre-start-up reviews, and so on. The following discussion of the review process will deal with project reviews associated with capital projects and focus on the area of process safety. 

Rigorous design reviews must include the often highly complex resonance behavior of impellers and blading to ensure vibration-free or vibration-tolerant design of these critical turboexpander components. In other words, the manufacturer must perform comprehensive theoretical and experimental studies of the blade oscillations in the rotating system. 

Prevention costs - These are eosts we expeet to ineur to get things right first time, for example quality planning and assuranee, design reviews, tools and teehniques, and training. 

Design reviews are a formal proeedure to establish the total understanding and aeeeptanee of a design task. The purpose of reviews is to (Parker, 1997) ... 

Improvement of equipment effectiveness. This should start with a detailed design review of the plant machinery. A performance analysis of the plant could point to a specific area known to have problems (i.e., section of plant) must be selected and focused on, project teams should be formed and assigned to each train. An analysis should be conducted that address the following ... 

Designs should be based on knowledge of what the human body (and human nature) will do. Include educated operators in design reviews. The HAZOP methodology for process hazard analysis offers an excellent opportunity to identify design and procedural opportunities for inherently safer systems. After all, the OP in HAZOP stands for operability (COPS, 1992). For example, a safe start-up procedure that requires the operator to walk up and down the stairs three times to manipulate valves in the correct sequence can be made inherently safer by locating the valves so that operator has to walk up the stairs only once during the start-up. 

In one site, the project team installing a DCS (Distributed Control System) carefully developed and tested techniques to make the displays clear for red-green color blind personnel (see discussion in 6.4). The displays were effective and were applauded by the operators. However, in subsequent DCS installation projects at the same site, different project teams made no provision to make displays visible to red-green color blind personnel. This inherently less safe condition was found during a design review at one unit and at the pre-start-up safety review for another unit. 

McCarthy, A. J., J. M. Ditz, and P. M. Geren (1996). "Inherently Safer Design Review of a New Alkylation Process." 5th World Congress of Chemical Engineering, July 14-18, 1996, San Diego, CA, Paper 52b. New York American Institute of Chemical Engineers. 

Guidelines for Control Room Design Reviews, September 1981. 

This design review example has illustrated the following points ... 

Do the design controls ensure that design reviews and design verification and validation are recorded and demonstrate the product meets the design input and user requirements ... 

The standard doesn t require a procedure for Management Review and while it does require procedures for Design Control it does not specify that a Design Review Procedure is required. The phrases consistent with and in accordance with have the same meaning as both imply compatibility and agreement. If you restrict yourself to a literal interpretation of the standard, you need produce no more than 43 documented procedures - possibly less if some aspects do not apply to your business. You can combine several procedures in one document, the size of which depends on the complexity of your business. The more complex the business the greater the number of quality system documents. The more variations in the ways that work is executed, the larger the quality system will need to be. If you have a small business and only one way of carry-... 

Project reviews are not design reviews. Project reviews assess performance of the project and take into account timing, costs, organization, work assignments, subcontracts, etc. Design reviews look back at the technical aspects of design and look forward to the technical aspects of the design tasks ahead. 

Details on what is required are given in section 2 of the APQP manual. However, the design reviews carried out at strategic stages during development should address manufacturability and so, rather than conduct one feasibility review, you should plan a review as part of each design review. 

Design for Manufacturability and Assembly Plan Design review reports Prototype control plan Engineering drawings and specifications Material specifications... 

Establish project reviews as separate reviews from design reviews. 

Interfaces should be reviewed along with other aspects of the design at regular design reviews, scheduled prior to the completion of each phase or more often if warranted. 

A schedule of design reviews should be established for each product/service being developed. In some cases there will need to be only one design review after completion of all design verification activities. However, depending on the complexity of the design... 

Conceptual Design Review - to establish that the design concept fulfills the requirements before project definition commences... 

Critical Design Review - to establish that the detail design for each sub-element of the product/service complies with its development specification and that product specifications have been produced before manufacture of the prototypes... 

The input data for the review should be distributed and examined by the review team well in advance of the time when a decision on the design has to be made. A design review is not a meeting. However, a meeting will often be necessary to reach a conclusion and to answer questions of the participants. Often analysis may need to be performed on the input data by the participants in order for them to determine whether the design solution is the most practical and cost effective way of meeting the requirements. 

---