Python Machine Learning Engineer
March 20, 2021
How Nobian Avoided €980k in Losses with Short Interval Control
May 11, 2021Many digital transformation initiatives in manufacturing environments focus on technology and systems, neglecting end-users’ needs. This often results in low user engagement and suboptimal outcomes. In fact, based on a Forbes article, 70% of digital transformation initiatives fail, underscoring the challenge.
As the industry increasingly focuses on Overall Equipment Effectiveness (OEE), ensuring high user engagement with OEE tools has become critical. Without active user participation, the quality of data collected for decision-making drops significantly, rendering it low or entirely ineffective. This undermines manufacturers’ efforts and blocks opportunities to measure and improve operational efficiency.
In just 2½ months, Cyzag’s OEE solution delivered significant savings for Nouryon and was scaled to 23 global plants within 6 months.
The Challenge
In the process industry, software functionality and tools are often not defined with users in mind. Instead, there is a high focus on technology, platforms and system architecture rather than people. We found a clear example of this while implementing the Cyzag platform at global speciality chemicals leader Nouryon.
Nouryon and Cyzag set out to understand and increase process operator engagement by implementing the Cyzag platform’s OEE tool. While the existing system was functionally capable, it lacked context, hindering operator efficiency. Several pitfalls in the old tool were identified:
- The data structures created, while theoretically sound, were challenging for a user to understand.
- Users needed to use multiple tools to collate the data to perform one action.
- The context of the manufacturing process did not exist in the current tool.
- Users did not see the value in using the tool or in the underlying operational excellence processes.
The Solution
In close collaboration with Nouryon, we launched an experimental initiative to explore the possibilities of trying something new for the company. Cyzag sought to create an intuitive tool that required no extra training, consolidated all data, ensured integrity, and could be easily deployed to new sites. Importantly, Cyzag decided to build on data visualisation concepts that were already familiar to the company, ensuring the tool was user-friendly for operators.
The Pilot Project
We initiated a pilot project, completing it in just 2½ months to demonstrate its value promptly. This pilot employed an assertive approach, applying design thinking principles. The underlying philosophy was to develop a tool for users that:
- It was intuitive (i.e., it did not need an associated training program/budget).
- Enabled operators to identify and track production issues, with all information in one place.
- Actively maintained the integrity of the produced data.
- It would be easy to install at a new site.
Modern manufacturing facilities are already data-rich environments, and operators are familiar with multiple data visualisation concepts. Early on at Nouryon, it became apparent that a shortcut to a successful outcome would be not to stray away from these familiar concepts.
The prototype of the new tool was implemented as a pilot project at one site, and its immediate impact was evident. At the first presentation, the operators spent 10 minutes familiarising themselves with the tool before using it to launch into a debate about a specific loss in the production process. This hands-on experience with the operators provided valuable insights for further improvements.
“The pilot took just two and a half months from conception to proof of value. Within 6 months of the pilot being complete the tool had been rolled-out to a further 23 Nouryon plants, with an ongoing initiative to deploy globally.”
The Results
At the sites where the Cyzag platform had been implemented:
- An average of €400,000 has been saved per plant per year.
- Operator engagement has substantially increased 4x compared with legacy systems (see Fig.2).
- Transfer of decision-making to the shop floor – operators took over root-cause problem-solving.
- Overall, it increased the operators’ knowledge and visibility of process efficiency.
- Operational excellence processes are being adhered to.
- Operators were able to prevent losses before they happened.
“Return on investment has proven to be well within requirements of the company.”
Within 6 months of the pilot’s completion, the platform had been rolled out to 23 Nouryon plants. This includes an ongoing initiative to deploy globally.
Conclusion
User-centric tools drive manufacturing excellence, minimise losses and achieve significant savings, as showcased in this impactful case study. Therefore, putting users at the core of digitalisation and engaging operators can significantly enhance operational performance, highlighting their importance. Finally, major performance improvements do not need lengthy, expensive digitisation programs. Selecting parts of the operation where there are opportunities, results can be delivered in weeks with exceptional ROI.
Want to learn how Cyzag’s platform can work for your manufacturing plant? Book your personalised demo today.
