Digitalization / Industry 4.0 in chemical production and distribution
Compared to other sectors, the topics of "digitalization" and "Industry 4.0" are still in the development stage in the chemical industry. Comprehensive digitalization programs are the exception rather than the rule. Individual solutions that address selected topics are more common. For example, anomaly algorithms can be used to predict the failure of a plant component. Advanced Process Control keeps a process automated in a specific window or provides information to plant operators.
However, automation not only improves processes. It is also a key factor in solving the demographic challenge: in the next two to three years, it is estimated that 30-40% of the industry's workforce will be replaced, and with it their expertise. Closing this gap is becoming increasingly difficult, especially as shift work is also becoming less attractive. This is where automation and digitalization can make valuable contributions: e.g. by digitalizing expertise and reducing the need for personnel for work that appears less attractive.
Demand-driven digitalization and automation
Many industry representatives consider business cases for digitalization solutions to be ultimately unsustainable. In fact, it is essential to ensure that the digitalization strategy is closely derived from individual business requirements. This is the only way to ensure that this is not a technology-driven process – but that digitalization is geared towards actual needs and thus finds acceptance.
With a view to acceptance, it is necessary to involve the organization in the implementation of the solution. For example, to allay the concerns of technical employees that digitally supported, predictive maintenance will make their work "superfluous". This opens up new opportunities to use time in a more value-adding way and to incorporate new, interesting tasks. New forms of collaboration with suppliers can also emerge, e.g. by automatically exchanging data on production progress, stock levels and much more along the value chain.
Further services for the chemical industry
CLIENTS
CASE STUDIES
Lean Digital Manager
Shaping the factory of the future with Lean 4.0. How can lean principles be combined with the technologies and possibilities of networked digitization in value creation networks? By further qualifying employees to become decision-makers. The ROI-EFESO certification program for "Lean Digital Manager" shows how digitalization of lean production works. To do this, it combines strategies with Industry 4.0 technologies.
Smart Factory Planning: Smart Planning for smart Factories
What does the ideal factory of the future look like? Do products there control their production completely independently? A pharmaceuticals and life sciences company plans the main directions for the smart factory transformation of four plants in just one month. Together with ROI-EFESO, the project team creates a "big picture" as a basis for planning and tests three prioritized technologies in pilot projects.
Business Operations Strategy: Re-start for production networks
A market leader strengthens its Global Footprint structures. With a turnover of around EUR 10 billion, the company is one of the market leaders in the life science and chemicals sector. After a long period of successful global growth, developments such as tougher competition and shifts in demand between regions are jeopardizing the achievement of the ROCE (return on capital employed) targets.
Manufacturing Excellence: Optimizing instead of improvising
The global demand for thermosets is increasing, as is the case in the energy industry. A manufacturer of thermosetting resins has positioned itself as a leader in the chemical industry by providing these customers with a variety of innovative technologies, solutions and specialty products. In order to be able to react even more efficiently to market changes and customer requirements in the future, the company is realigning its production network.
OPEX: Redesign of the organization
The demand for high-performance plastics is increasing worldwide. A company in the chemical industry wants to increase the total capacity of its polymer production by more than 50% with a new plant complex. Together with ROI-EFESO, it is aligning its organizational structure to growth and profitability and is realizing an annually recurring benefit of more than EUR 1.5 million through process improvements.
Chemical company on the way to climate neutrality
In order to achieve the self-imposed goal of being climate-neutral by 2050, a manufacturer of basic chemicals has to put its entire business model to the test. ROI-EFESO supported the client with robust scenario planning to develop a sustainability roadmap that enables sustainable growth in a challenging industry environment.
Sustainable Chem: New start for the organization
In order to achieve the self-imposed goal of being climate-neutral by 2050, a manufacturer of basic chemicals has to put its entire business model to the test. ROI-EFESO supported the client with robust scenario planning to develop a sustainability roadmap that enables sustainable growth in a challenging industry environment.