Operational Excellence in the Chemical Processing Industry (CPI)
OPEX (Operational Excellence) projects in the chemical industry are geared towards a comprehensive improvement of the respective company's value creation processes. In the European environment, energy prices, feedstock and regulatory framework conditions put companies at a disadvantage in global competition, particularly compared to the USA and Asia. This requires the best possible use of resources to maintain competitiveness.
At the same time, holistic optimization approaches offer plenty of scope to leverage significant potential. For example, driving parameters can be optimized in a very targeted manner using digital tools: yield, rate, batch cycle times and ramp-up /ramp-down can be improved. In addition, many potentials can be activated through standardization and system availability losses can be effectively addressed – for example by optimizing cleaning and product changeover times or using autonomous management / maintenance systems. In addition, the interface between production and maintenance is an area that significantly determines the level of performance and availability of a system and offers starting points for further developments.
Advancing OPEX cross-functionally
In the past, chemical companies often focused on selective improvement initiatives, e.g. separately for production or maintenance. Today, they are increasingly moving towards setting up holistic OPEX programs. This cross-functionality is also an important prerequisite for establishing truly sustainable and comprehensive improvements. Particularly with a view to sustainability, these programs go hand in hand with the development of an internal infrastructure for change. In other words, targeted investment is made in internal expertise in order to autonomously drive the continuous improvement process forward.
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.