The average lifespan of assets in the chemicals industry has increased over time, and as a result, the associated maintenance work has significantly increased along with it. As per some estimates, 50% of fixed costs for a typical chemicals plant are the result of continuous maintenance work. This maintenance work can be classified into three categories: reactive, preventive, and predictive.

Reactive maintenance

As the name suggests, reactive maintenance is performed after something breaks down. When a company dedicates a significant amount of its time, money, and resources to conducting reactive maintenance, the company typically “pays for it” in the form of schedule interruptions, rescheduling, lost volume/sales, lost customers, lower pricing power to attract new customers, fines and charges, etc. While cutting maintenance costs may look profitable, a complete assessment of all side effects would likely prove otherwise. In fact, the total cost of reactive maintenance can turn out to be two to three times higher than a preventive maintenance approach.

Chemicals and life sciences manufacturers like you have unique requirements when it comes to your manufacturing operations. Infor SyteLine® for Chemicals is built on 30 years of manufacturing solution expertise and a Process Industry Pack, making it easy to adjust formulas, build batches based on exacting manufacturing specifications, and monitor and respond to the evolving regulatory environment.

Flexible formula management

Process manufacturers like you need a formula management system that helps develop formulas that account for factors like solubility and total yield. You need a system that has the flexibility to resize formulas to produce batches based on percentages, not quantity amounts. Infor® SyteLine for Chemicals provides the unique materials management and product customization functionality you need.

In part one of this post we explored how to manage supply chain complexities and unpredictability. In this second part, we’ll help ensure chemical manufacturers don’t fall into a pattern of bad planning and skillfully anticipate seasonality.

To operate at its peak an enterprise needs to face and recognize the top trends that are reshaping manufacturing. Understanding these trends is the first step toward initiating a digital transformation. You can then take the additional steps designed to solve your business’ current problems, start showing value immediately, and help evolve a stronger business strategy.

Supplier seasonality and promotions

Thankfully, not everything about supply and demand is unpredictable—materials in the supply chain in various parts of the world follow their own, reasonably predictable seasonal patterns. For instance, cotton prices from India (the largest producer of cotton in the world, according to Statista) plunge when the harvesting begins in November, and stay low though when harvesting ends in March of the following year. This, obviously, has a significant impact on the fiber-garment industry.

To stay competitive in today’s chemical industry, manufacturers must sustain a high level of operational productivity. Moreover, current issues like rapid commoditization, complex supply chains, aging assets, and increased need for dynamic operations planning make it more demanding than ever before to achieve the level of productivity that drives differentiation and innovation. Manufacturers often become locked into patterns where they’re implementing shortsighted cost-cutting measures that can adversely affect operational productivity and decrease overall market responsiveness.

To ensure you don’t fall into these traps, it’s vital that you not only understand the industrial challenges you face, but also recognize the top trends that are reshaping manufacturing. Gaining this knowledge is the first step toward building a foundation of digital transformation.

This blog post is a helpful summary of the top challenges a supply chain faces today. If you’d like to learn more about how to turn these obstacles into opportunities, please read Infor's recent executive brief for an even deeper dive into the topic.

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