Operational Excellence: €400k Savings in 8 Weeks
The 5 Principles of Continuous Improvement in Manufacturing
October 27, 2023
Routine Management
November 20, 2023
The Challenge:
Transforming Manufacturing Operations with Cloud Technology
In the dynamic world of chemical manufacturing, unlocking the potential for efficiency and cost savings is a continuous challenge. The rise of Industry 4.0 brings great potential, but slow execution often hampers progress, hindering digital manufacturing evolution. Many plants face common obstacles, burdened by legacy tools, lack of support, and outdated systems. As well as, limited data maturity and a lack of contextual information compound daily challenges.
Traditional manufacturing software projects are infamous for lengthy implementation, large teams, and hefty budgets. Often resulting in inflexible tools that fail to meet user requirements, delaying ROI.
With this in mind, we embarked on a significant project with a global chemicals company, demonstrating the Cyzag platform’s value.
The Solution:
User-Centric Cloud-Based Software for Operational Excellence
The Cyzag platform is a highly focused, cloud-based technology tailored to the specific requirements of process manufacturing. Cyzag places user-centric design at its core, reducing the learning curve and minimising the need for extensive training.
Operators were vital in the implementation process, ensuring the software not only enhanced their work experience but also empowered them to make informed decisions rapidly, cultivating a culture of operational excellence.
The success in moving decision-making to the shop floor started with four steps:
- Giving shop floor operators easy access to useful data.
- Overlaying data with meaningful context and adding real-time alerts improves an operator’s ability to react to a given situation.
- Promoting collaboration between operators, shifts and engineers by capturing and making visual decisions and process events.
- Providing feedback on past performance.
Cloud-based technologies made it possible to consolidate data from multiple sources and are available through a browser – either to an operator on the shop floor or a manager at headquarters. The Cyzag platform has a no-code/lo-code design that enables rapid configuration in any plant or process, offering an extensive library of ready-built models and reducing configuration time. Benchmarking plants and sites is easy and quick.
The Results:
Revolutionising Manufacturing Excellence for Cost Savings and Increased Operator Engagement
Implementing the Cyzag platform has yielded significant results in just 8 weeks. The rapid value realisation started with the first pilot site in South America and, within 12 weeks, expanded to a second plant. Over the following six months, it was implemented at 21 of the company’s plants in 11 countries. Even during the COVID-19 pandemic, the rollout continued, with over 65 sites adopting the solution, typically within 3-4 weeks of the implementation.
This approach has had a substantial impact on cost savings and operator engagement, with an average of €400,000 saved per plant per year.
Savings were identified and ROI was proven in weeks, thanks to a standardised approach for gathering and contextualising process performance data, user-centric cloud-based software, no-code/low-code design, and an extensive library of ready-built models. And through direct user feedback Cyzag continually evolves, ensuring value is consistently delivered throughout the software’s lifecycle.
Are you ready to unlock the potential of digitalising your manufacturing plant? Contact Cyzag to learn more about how our platform can work for you!
