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Batch House Audit Program and Maintenance Planning

Structured audit and capacity assessment program for reliable, data-driven batch house capital and upgrade planning

Capabilities Demonstrated

  • Batch automation and sequencing analysis
  • Cycle time and throughput studies
  • Process and mechanical engineering
  • Maintenance and reliability assessment
  • Capital project planning with ROM cost estimation
  • Technical documentation and reporting
  • Multi-site program development and scheduling

The Challenge

Many corporate capital project teams operate without a clear and up-to-date understanding of their batch house baseline conditions. Over time, plant modifications, process changes, and aging equipment lead to uncertainty around system performance, reliability, and capacity. This lack of visibility prevents teams from accurately planning critical maintenance events, identifying risk areas, and developing realistic budgets for future capital projects.

Glass manufacturers often approach Re:Build Optimation seeking third-party expertise to assess their batch houses, benchmark current performance, and create actionable plans for both short-term maintenance and long-term capital investment.

Approach

Re:Build Optimation developed a structured audit process designed to evaluate both system condition and operational capacity across the entire batch house. The program includes two core focus areas:

1. Capacity and Cycle Time Analysis

  • Conduct detailed time studies of batching operations to identify throughput bottlenecks and cycle time inefficiencies.
  • Analyze mixer, scale, and delivery timings to determine available capacity improvements without major equipment changes.
  • Recommend low-cost operational adjustments and system modifications to increase output and optimize existing assets.

2. Maintenance and Condition Assessment

  • Perform full-system evaluations from raw material unloading through batch delivery to day bins.
  • Use a standardized color-coded grading system (Very Good, Good, Fair, Bad) to rate equipment condition and maintenance risk.
  • Capture visual documentation, maintenance history, and operator feedback to support each recommendation.
  • Develop prioritized lists of maintenance and capital projects with Rough Order of Magnitude (ROM) cost estimates.

Audits are scheduled on a three-year recurring cycle, optimized to minimize travel costs while maintaining audit quality and continuity between sites.

Solution

Each completed audit results in a comprehensive report, typically 30 to 60 pages, detailing Re:Build Optimation’s findings, analysis, and recommendations. Reports are tailored to each plant’s goals, whether focused on extending equipment life, improving throughput, or planning for upcoming furnace rebuilds.

The report provides:

  • A clear picture of current batch house condition and performance
  • Specific maintenance priorities and replacement recommendations
  • High-level capital project planning with ROM cost estimates
  • Cycle time analysis and throughput optimization opportunities

The insights enable plant teams to make data-driven decisions that balance risk reduction, production goals, and capital allocation.

Results

Re:Build Optimation’s Batch Audit Program provides manufacturers with a structured, repeatable method for understanding batch house performance, maintenance risk, and capital improvement opportunities. By combining engineering analysis with on-site evaluation, the program quantifies capacity, reliability, and lifecycle impacts, enabling teams to evaluate return on investment, prioritize projects, and build defensible business cases for capital funding.

This proactive, data-driven approach reduces unplanned downtime, supports informed budgeting for major upgrades, and identifies opportunities for measurable improvements in throughput, waste reduction, and equipment reliability. The result is a clear path from audit findings to funded projects that deliver tangible operational and financial results.

System Overview

  • System Type: Batch house performance and maintenance audit program
  • Function: Evaluates system condition, throughput capability, and maintenance risk across all batch house operations
  • Key Features: Time studies, capacity benchmarking, condition grading, visual documentation, ROM cost estimates, and multi-site reporting
  • Scope of Assessment: Raw material unloading, storage, batching, mixer and scale performance, delivery systems, and day bin feeding
  • Deliverables: Comprehensive audit reports, prioritized maintenance actions, capital planning guidance, and cycle time analysis
  • Deployment: Scheduled on a three-year recurring cycle for consistent benchmarking across multiple facilities

Benefits & Impact

  • Improved visibility into batch house performance and equipment condition
  • Actionable recommendations for maintenance and capital improvement planning
  • Identification of throughput and capacity gains with minimal investment
  • Reduced risk of unplanned downtime through proactive maintenance planning
  • Data-driven budgeting for future furnace rebuilds and major projects
  • Consistent benchmarking across multiple manufacturing sites
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