Global competition along with squeezed profit margins due to high feedstock and energy prices are requiring that chemical companies better utilize their existing assets. The challenge becomes greater when dealing with a graying and/or inexperienced workforce. As pressure increases for “greener” products, many manufacturers are finding it increasingly difficult to meet demand while continuing to maintain regulatory compliance.
IPS can help with solutions that improve yields, agility, and workflow management so that problems with scheduling, product demand, product variations, yields, and maintenance are identified early. In addition, we can help analyze root causes and make recommendations to empower plant personnel to make faster, better business decisions, at the right time in the right context, enabling them to implement corrective actions before any problems or variations occur. In this way, product variability and product demand are managed better and month-end surprises avoided. The right information gets to the right person at the right time. Product yields and manufacturing capacity is greatly improved as well as reduction in waste and product variability.
To address the challenges and unique requirements of the chemical industry, IPS brings together key elements from our comprehensive product portfolio with powerful solutions including:
- Critical Asset Management transforming your operations to a predictive and proactive approach encompassing operations, maintenance and supply chain to accelerate production, reduce lifting costs and extend asset life
- Operator & Engineering Effectiveness enhancing overall team productivity and utilization through right-time scenario evaluation, training and critical situation management while providing a highly productive and intuitive environment with templates that enable consistent, high quality engineering solutions in a collaborative environment
- Maintenance Effectiveness providing the required availability at the lowest possible cost through best practices and advanced techniques including Condition Based Maintenance and Reliability Centred maintenance.
- Real Time Finance providing global visibility to all key performance indicators and the financial impact of operational decisions
- Production Optimization for Batch Industries improves plant economic performance by increasing production yields and agility by improving visualization, anticipating supply chain demands and predicting problems or variations before they occur
All of these solutions are enabled by the global industry experience embodied in our Global Consulting organization. This world class team works with our clients to identify the issues and opportunities and develop the strategy, action plan and ROI for the necessary solution components.
By accessing and integrating data from multiple disparate systems, our solutions easily empower plant personnel with the ability to identify potential problems before they arise. The benefits of using this solution are significant and measurable. Based on our experience, an average of 1- 5% of the total output value per plant – or at the enterprise level – in lowered costs or increased revenues can be realized using this approach.