Transforming a Chemical Manufacturer into a Lights-Out Operation

THE PROBLEM TO SOLVE

Modernization projects often begin as a mix of long- and short-range goals. A leading chemical manufacturer that GrayMatter works with has a long-term goal of running a fully automated, "lights-out" operation.

But in the short term, company leaders sought GrayMatter’s help to refine or eliminate manual processes, reduce downtime and replace outdated equipment.

Heavy reliance on manual downtime tracking
Lack of real-time data analytics
Outdated historian systems, leading to inefficient data usage and decision-making
Adapting modern technology into legacy systems without disrupting production flow

SOLUTION

To address these challenges, GrayMatter developed a comprehensive solution under our Brilliant Operations Offering designed to resolve the company’s short-term challenges and set it on a path to its long-term goal of establishing a “lights-out” factory.

GrayMatter's Brilliant Operations solution included:

Implementing Banner Wireless data collectors to modernize and gather data from legacy equipment seamlessly
Instituting a suite of software solutions including IGS, Historian, Plant Apps and Ops Hub to streamline operations and enhance data visibility
Beginning downtime tracking for more than a dozen machines, setting a foundation for expanding automation and data analytics capabilities
Planning expansions into quality management and ERP system integration, alongside the development of custom dashboards for better operational oversight

The team’s efforts have already started to produce results. A major factor in the project’s early success was a smooth kick-off. GrayMatter’s team completed software installations during the initial visit thanks to the company's diligent preparation and adherence to guidelines provided in advance.

GrayMatter's Brilliant Operations Offerings helps companies reimagine the way they think about infrastructure, digital tools and the people who use them. It's designed to allow organizations to scale quickly, make a business case for optimization efforts and leverage the best technologies and processes available.

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RESULTS

Reduced Downtime

Enhanced machine utilization and reduced downtime through effective automation and real-time tracking

Better Decision-Making

Improved decision-making processes due to restored historian connectivity and access to historical data

Operational Efficiency

Saw a marked increase in operational efficiency

Strong Foundation

An established foundation for phase two, which includes extending the automation to over 160 assets, integrating quality management and more

Positive Feedback

Positive feedback on the ease and efficiency of the software, underscoring a successful partnership and technological implementation

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