Chemicals Right First Time | Marchington Consulting

Technical team improves in process quality three-fold
Solving Right First Time failure – chemical process

Business

Owner:

Multinational Chemical Company

Objective:

Improve in process right first time from baseline of 36% in previous year to >75% by end of Q4 in order to reduce re-blending, out of spec WIP and complaints

Results:

• Successfully met targets, subsequent years demonstrated the effectiveness of the approach and its sustainability

• 85% market share defended and improved upon

Approach

On the job coaching for a small client technical team, using our proprietary problem solving approach:

• Build KPI deck to understand and prioritise failure modes

• Use fault tree approach to determine perfect world and actual raw material and process variables on top ten grades, roll out to next 16 grades

• Develop new early stage test protocol and in-flight correction method, re-formulating recipes and thermal profile where required

Build new process visualisation tool with trend and alarms to detect potential process failure before it happens

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