Benefits of advanced analysis in the chemical industry (Part 1)

The application of digitization in management systems provides a promising vision for chemical companies to use advanced analytics to improve quality productivity as well as improve competitiveness in the market.

Reduce downtime through advanced analysis

Advanced analysis is one of the typical applications that can only be used with the aid of a modern computer system integrated with information collection tools such as sensors, internet of things (IOT), etc any chemical companies have begun to realize the potential of this application.

Large-scale chemical manufacturers often have problems with circulation pumps and discharge pumps at their large factories. If one of the pumps is broken, the plant must stop production for ten hours while installing the replacement. This not only caused great economic losses but also disrupted the production process, causing the process to start over. On the other hand, the cost to repair or replace these pumps is not small.

To solve this problem, some manufacturers have conducted tests to find out the cause of frequent broken pumps and find remedies. They tried using alternative materials for the pump as well as applying many different processes, but none of them could solve the problem.

Until advanced analytical techniques were put into use, the knot began to be removed. This method can increase the life of important equipment such as the above pumps by using big data (Big data) to find the repetitive points each time the device fails. By continuously collecting data in real time, the computer system will automatically analyze and give suggestions to solve the problem before it happens. This method is called predictive maintenance. Through monitoring all relevant parameters and always ready to replace the device when a problem occurs, it is even possible to intervene before it happens and limit all incidents. Maintenance estimates often reduce downtime by 30-50% and increase machine life by 20-40%.

Another example: At Bosch, by immersing sensors into entire machine systems and analyzing the data obtained from them in real time, Bosch engineers can predict possible failures. out. This allows them to cut down on unplanned downtime through performing preventive maintenance. Bosch reported that this method helped the company to increase production by 10% in some areas, while shortening delivery times and improving customer reputation. Over the past four years, Bosch has earned more than 1.5 billion euros thanks to Industry 4.0 applications.

(To be continue)

Productivity and Quality Office