The chemical industry must increase operational efficiency, maintain consistent product quality, while ensuring costs hold steady and consumer demands are met. The challenge is visibility into processes to ensure efficient production.
Challenges
Market variability and pressure
Before the pandemic, nearly 50% of the top 100 chemical companies made changes to their product portfolio (McKinsey)
Productivity and fixed-asset utilization
From 2011 to 2020 the quantities of production-related waste managed by the chemical manufacturing sector increased by 79% (EPA)
Workforce effectiveness
30% of skilled labor force is over 50 and expected to retire in the next 15 years (US Chamber of Commerce)
Environmental, Social, and Governance (ESG)
Including fuel and feedstock use, the chemical industries account for about 30% of the total energy consumed in the manufacturing sector (EIA)
Batch Performance Analytics is a solution that helps you consistently produce batches within set specifications; the “Golden Batch”. Identify contributing factors in production variability and helps to improve regulatory compliance by automating data collection, analysis, and reporting of continued process verification.
Expected outcomes
Accelerated growth through digital transformation
Unified operations platform
Manufacturing operations management
Batch performance analytics
Production optimization
Unified process and power control
Advanced analytics
Asset performance management
Workforce enablement
Digital work instructions
AR/VR Connected worker
Sustainable operations
WAGES management
Decarbonization of operations
Advanced continuous emissions monitoring
Unlocking the Golden Batch
Define multi-level KPIs (for critical production steps and for the overall batch) for example quality, yield, throughout and cycle time.
- Tie KPIs to PP/CPP and COAs
- Configure KPIs/Set the Golden Batch
- Drill down to analyze single KPIs
- Multi-site performance comparison
- Agnostic connectivity to disparate data
- Receive alerts and adjust process parameters
