Cost reduction, OEE improvement and automation blueprint design in a chemical manufacturing unit

Problem statement – A chemical company was facing issues with higher fixed cost and poor OEE.

Our approach –

1. Identified opportunities in reducing utility cost and overheads through organization design

2. Mapped processes and identified opportunities to introduce automation to improve productivity and reduce utility cost

3. Redesigned and implemented work processes for utility cost reduction

4. Used statistical process control methodology to reduce process variation and improve Cpk

5. Implemented work order system in maintenance to improve wrench time and reliability program such as predictive maintenance and bad actor improvement

Results –

1. Reduction in utility cost by 12%

2. Reduction in overheads by 15%

3. Improvement in OEE by 10%

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