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 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 multi-generational planning
- Requirements of customers, key users, and stakeholders
- Concept alternatives and good practices
- Detailed improvements, flow, and ergonomic requirements
Coordinate all aspects of the process, ensure mutual understanding and reduce subsequent changes

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

Improvement of investment decision reliability through dynamic modelling simulations 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

Profitability improvement by establishing a unified Business 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.