Cost and time savings through the application of lean principles in plant construction in the chemical industry

Initial situation

An international chemical company had grown considerably and needed to expand capacity at existing sites and build new ones
Previous plant construction projects suffered from problems such as late changes that led to increased costs, delays and unfulfilled requirements
Later, the production facilities had to be optimized through continuous 5S and improvement projects
The idea of a lean approach to plant construction and directly correct planning and execution from the outset became increasingly important
A systematic approach to project implementation should be developed

Acceptance

of the new production lines increases

The cost and time deviations are reduced

Lean

Integrated principles

Systematically improve plant engineering project phases, in particular pre-basic, basic, detail engineering and commissioning
Set up cross-functional teams to achieve coordinated results in a series of workshops with a focus on
- Goals, capacities and multigenerational planning
- Requirements from customers, key users and stakeholders
- Concept alternatives and best practices
- Detailed improvements, material flow and ergonomic requirements
Coordinate all aspects of the process, ensure mutual understanding and reduce subsequent changes

Increasing performance orientation through a supply chain target operating model in the chemical industry

Increased reliability of investment decisions through dynamic modeling in the chemical industry

Establishing global innovation excellence by introducing an agile innovation process

Improving employee satisfaction through AI-supported evaluation of surveys in the chemical industry

Improving profitability by establishing a living excellence initiative in the chemical industry

Global rollout of a production system through a lighthouse approach in the chemical industry

All cases

Discover more references.