How a Chemical Manufacturer Saved €400k in 8 Weeks

In just 8 weeks, a global chemical manufacturer saved €400,000 by transforming its plant operations with Cyzag’s no-code platform. The goal was to overcome legacy system inefficiencies, reduce downtime, and empower operators to make data-driven decisions at the point of action. What began as a single-site pilot, then scaled to over 65 global locations, proving digital change can be quick and cost-effective. With a flexible, scalable approach, the transformation delivered immediate ROI and demonstrated impactful change across multiple sites.

The Challenge:

Transforming a Chemical Manufacturer’s Operations with Cloud Technology

In the fast-paced world of manufacturing, the pressure to modernise is constant. However, many manufacturers still struggle with outdated systems and inefficient processes that hinder their ability to keep up with the demands of Industry 4.0. A global chemical manufacturer faced these exact challenges, compounded by:

• Legacy software that was slow and difficult to integrate

• Lack of data visibility and meaningful insights at the operator level

• Inefficient and error-prone manual processes

• Delays in realising ROI from traditional software projects

The company needed a rapid, cost-effective solution to jumpstart its digital journey and reduce inefficiencies quickly.

With this in mind, we embarked on a significant project with a global chemical manufacturer, 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 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!