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

Initial situation

An international chemical company had developed a production system and needed support to roll it out worldwide
Global competition and the need to reduce production costs required efficient and standardized processes
More than 100 locations worldwide, different cultures, production processes and standards presented the company with a challenge during the rollout
Potential should be leveraged through standardization and continuous improvement in order to reduce costs

Production facilities converted to new production system

0 million €

Costs reduced

Lean

Principles firmly anchored in the production process

Establish lighthouses to illustrate the target state and demonstrate added value in practice
Introduce the production system where it can help with local pain points to increase acceptance
Establish targeted key figure systems for control
Identify end-to-end processes to leverage potential for improvement
Roll out store floor management in conjunction with end-to-end process optimization
Consider lessons learned and lean principles when planning new factory buildings

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All cases

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