In the world of petrochemical manufacturing, the efficiency of operations depends on the seamless performance of multiple process and equipment units. Industry leaders are increasingly adopting big data technologies and analytics to automate production processes, integrate machinery, track performance, and predict equipment malfunctions—critical advancements for enhancing operational efficiency and productivity.
Our client, a leading global petrochemical major, recognized the need for robust digital transformation initiatives. Despite their progress in automation, they encountered significant challenges with legacy systems. Traditional methods for asset performance and reliability proved inadequate in proactively addressing asset breakdowns or plant shutdowns, often lacking the necessary lead time for preparation and mitigation. Moreover, ineffective monitoring of critical Key Performance Indicators (KPIs) led to operational inefficiencies, causing material losses and leakages during the manufacturing process.
This case study examines how transformative solutions have helped this petrochemical giant to overcome these challenges, resulting in substantial advancements in operational excellence, innovation, and significant cost savings.