Formaldehyde plant operational excellence catalog
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Operational Excellence Model for Formaldehyde and resins Plant Catalog.

Operational Excellence Model for Formaldehyde and resins Plant Catalog.

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Formaldehyde plant operational excellence catalog Document Transcript

  • 1. Improving plant performance through Operational ExcellenceFormaldehyde industries
  • 2. If you’re in the formaldehyde industries you need the right strategy Formaldehyde plants Formaldehyde is the most commercially important aldehyde. Urea-, phenol- and melamine-formaldehyde resins (UF, PF and MF resins) accounted for approximately 63% of world demand. Formaldehyde is a basic building block to many important industries, it is used to manufacture resins; as an intermediate for synthesizing other chemicals and is also directly used without further processing. Over 50% of consumption accounts on construction/remodeling activity, and to a lesser degree, the automotive industry. World consumption is forecast to grow at an average annual rate of 4.0% during 2009–2014. Demand for these markets is greatly influenced by general economic conditions. As a result, demand for formaldehyde largely follows the patterns of the leading world economies. The Today, all of the worlds commercial formaldehyde is manufactured from methanol and air using either a silver catalyst or a metal oxide catalyst. The silver catalyst process that combines dehydrogenation and oxidation to obtain formaldehyde is used by this end user with 100 TPD plant capacity. Most formaldehyde producers are concerned primarily with satisfying captive requirements for derivatives and/or supplying local merchant sales.Major Challenges & Opportunities Formaldehyde is usually produced close to the point of consumption since it is fairly easy to make, is costly to transport and can develop problems associated Volatile Methanol price. with stability during transport. As a result, world trade in formaldehyde is Utilizing Maximum plant efficiency. minimal day by day. Environmental Issues and air pollution. Lower Methanol yield. Be prepare for Future Higher Energy Consumption. Higher Start up time. Consistency in final product. Performance Improvement through OE Lack of awareness among employeetowards uses of Chemicals. Operational excellence model helps achieve business goals while lowering Shortage of Skilled Manpower in costs and improving cycle times. It standardizes processes and integratesOperation Process such as Engineering operations across multiple channels of supply and distribution, supportingand Production. high-volume, low-margin business strategies The Mattcons consulting team assists its clients to increase the value of their corporation, division, or individual facilities. Our consultants are focused formaldehyde specialists and have developed cutting edge methodologies for the analysis and integration of business solutions that withstand market cycles, and aims to maximize the enterprise value to the shareholder.
  • 3. Mattcons approach towards Operational Excellence. Value Proposition Increasing Profitability and Cash Flow Mattcons strategies, tools and techniques and our methodologies designed for improving business performance, improve equipment uptime (OEE), reduce scrap,Our Expertise improve yield, improve quality & productivity, accelerate set-up/change-over times, reduce lead times, optimize inventory.At Mattcons We look beyond costmanagement and focus on maximizing Driving Culture Changethe income-generating potential ofemployed capital. Our Consultants have Companies who successfully leverage operational excellence as part of a strategicdeep experience helping clients achieve platform for growth often achieve market performance well beyond their nearestand accelerate growth in their core competitors. We can help you how to expand continuous improvement into non-business and beyond. Combining manufacturing areas, how to enhance sales force productivity, how to optimize thecreativity and analytical insight with maintenance activities and enforcing the employees in all level.client engagement, our approach helps Supporting Growth Initiatives and New product developmentclients overcome both external andinternal barriers to growth. We will share best practices for applying process excellence to new product development and commercialization, Efficient product development processes closely integrated with the operational processes . You will gain important advantages, such as reduced lead time to market, improved quality and increased development capacity.Key Results Beyond the Basics Reduce Manufacturing Cost by 20 % Many manufacturing organizations need to expand continuous improvement Number of Breakdown reduced by 50% throughout the enterprise and seek training to expand capabilities into marketing, OEE improved by 30 % customer service, engineering ,new product development and quality control. Customer Complain down by 60% Supply Chain Management : The Real Improvement Inventory down by 30%Major Accidents reduced by 80% The complex and often costly internal supply chain processes is one area that manyImprovement of Suggestion 10 times businesses seek to improve. By “killing complexity” in the overall supply chain system, Improve 5S score by 80% companies will experience better, faster delivery with lower costs .Reduce Energy Consumption by 20%Consistency in final product by 60% Focus on Maintenance : Key for enhancing Profitability . Proper maintenance of plant equipment can significantly reduce the overall operating cost, while boosting the productivity of the plant. Hence another perspective of looking at maintenance function is not only to maintain but also to enhance the process or the plant operation system as a result of turnaround planning.MethodologiesTPM, 5S and SMED It is a program Lean Manufacturing that is more than just worthwhile. Value Chain and Value added analysis Management SystemStrategic Alignment Return Over Investment (ROI) RCM and TQM 10 to 33+ Folds of investment in Consulting fees.
  • 4. Pick our brains before Making your next move. E-mail : dsahoo@mattcons.com If you are interested in scheduling a no obligation 30 minute consultation to Phone : +91 - 902.900.5850 discuss any performance improvement. please contact:More About Mattcons MATTCONS Offering’s"We partner with clients in allsectors and regions to identify Management Consultingtheir highest-value opportunities, Lean Manufacturing Total Quality Managementaddress their most critical Reliabity centered Maintenance Supply Chain Managementchallenges, and transform their  Total Quality Management Operational Excellencebusinesses. Our winning  ISO Series Total Productive Maintenance.combination of local know-how,international orientation and Technical Consultingcustomized approach ensures that Vibration Analysis Motor Current Analysisour clients achieve sustainable IR - Thermography NDT techniquescompetitive advantage, build more Wear debris analysis Rotor balancingcapable organizations, and securelasting results. We seek to be Green Consultingagents of change—for our clients, Carbon Risk Management Carbon Pricingour people, and society broadly” Carbon Fund Management Carbon Neutrality Carbon Portfolio Valuation Carbon Rating (MATCARATS) Training and Certification Courses Public Seminar and Workshop Organization Development On -site Training (OST) Change Management On Job Training (OJT) Online Certification Courses Process improvement Certification Courses Projects Project Management Technical Support Pre project Engineering Services Decommissioning Contact Us Engineering Services Environmental services Construction and Field services +91-22-412-36302 Maintenance Products askus@mattcons.com CMMS - Computerized Maintenance management software . www.mattcons.com Operation Outsourcing  Operation Outsourcing  Manufacturing Outsourcing Mattcons Services Private Limited. Waghbill Naka, GB Road, Thane (West), Mumbai - 400607 Regd. Office – Kalyan Nagar, Pallahat, Khurda, Orissa, India – 752055