Reduction of cost and delays using LEAN principles in PLANT Engineering in the chemical industry

Initial situation

An international chemical company was growing and needed to expand capacities in existing sites and establish new sites
Previous engineering projects had faced typical problems, such as late changes that led to cost overruns, delays, and missed requirements
Later, the production facilities had to be optimized through continuous 5S and improvement projects
The idea of a Lean approach in construction and first-time right planning & execution from the very beginning became more and more prominent
The task was to develop and run a systematic project execution approach

Acceptance

Of the new production lines increased

0 %

Cost and time deviations reduced

Lean

Principles integrated

Systematically enhance the engineering project phases, particularly Pre-Basic, Basic, Detailed Engineering, and Commissioning
From day one, set up cross-functional teams to create aligned results in a series of workshops focusing on
- Goals, capacities and multi-generational planning
- Requirements of customers, key users, and stakeholders
- Concept alternatives and good practices
- Detailed improvements, flow, and ergonomic requirements
Align all aspects during this process, ensure mutual understanding, and massively reduce subsequent changes

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All cases

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