Digital Plant Management for Chemical & Plastics Manufacturers

The Right Formula for Chemical & Plastics Success

Precision is paramount. Insert visibility and tight process control into all facets of production.

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Digital Plant Management For Chemical & Plastics

Chemical and Plastics manufacturers are no longer just suppliers but value-driven partners. Answer the demands of today’s landscape by driving leaner operations, meeting evolving regulations, confronting limited visibility into plant performance, and expanding into new global markets.

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Cost Efficiency

Target waste, improve energy efficiency, and maintain data that meets the needs of stakeholders throughout the value chain.

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Consistent Quality

Identify and mitigate risk across the plant by emphasizing process control in every aspect of the operation.

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Optimized Production

Enhance overall equipment and labor effectiveness through better operational workflows, from sourcing to shipment.

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Simplified Compliance

Separate, identify and track the data, documents, and tasks required to avoid recalls and facilitate transparent audits.

Make the Unbelievable Achievable

Maximize Yield
10%
Decrease In Cost of Poor Quality
within 4 weeks of live data
Increase Productivity
35%
Lift in Line Level Throughput
and over 100% ROI within 90 days
Optimize Labor
70%
Increase in Labor Efficiency
and >$250K impact in 14 weeks

Deliver Quality Products At Lower Cost

  • Integrated SPC and SQC Tools: Leverage statistical process control (SPC) and quality control (SQC) tools that empower operators to monitor data in real-time during production. Enable your frontline to swiftly identify and rectify issues, eliminating variability and elevating product quality across the manufacturing process.

  • Track Testing Results: Easily track and manage formula testing results, including defect tracking and chemical analysis, associated with each lot or batch. Ensure comprehensive visibility into product quality and compliance from raw material to finished product.

  • Batch Yield Analysis: Dive into batch yield trends to identify opportunities for reducing raw material costs and enhancing overall cost-efficiency.

  • Integrated SPC and SQC Tools: Leverage statistical process control (SPC) and quality control (SQC) tools that empower operators to monitor data in real-time during production. Enable them to identify issues swiftly and manage one of your largest expenses, resin.

  • Centerline Tracking and Quality Optimization: Reduce scrap rates, rework, and defects per million (DPM) through precise centerline tracking, ensuring your products consistently meet quality standards.

  • Production Yield Trending: Analyze production yield trends by product/batch to identify opportunities for reducing resin costs and improving overall cost-efficiency.

Enhance Operational Visibility And Efficiency

  • Workflow Functionality: Create dynamic flows that allow for separate operators to complete checks in order and with minimal interruption. Streamline escalations for prompt issue resolution, ensuring compliance and better facility uptime, throughput, and run rates.

  • Real-Time Productivity Analysis: Track and visualize critical live measures of Overall Equipment Effectiveness (throughput, availability, and quality) within the production process. Accurately assess how efficiently any plant is running at any given time.

  • Analyze Top Loss Information: Monitor equipment availability in real-time to know the moment a downtime event occurs to more quickly address issues impacting productivity, enhancing capacity utilization.

  • Real-Time Productivity Analysis: Track and visualize critical live measures of Overall Equipment Effectiveness (throughput, availability, and quality) within the production process. Accurately assess how efficiently any plant is running at any given time.

  • Analyze Top Loss Information: Monitor equipment availability in real-time to know the moment a downtime event occurs to more quickly address issues impacting productivity, enhancing capacity utilization.

  • Manage Equipment: Work order and maintenance programs that improve visibility into parts consumption and equipment breakdown. Manage both scheduled and unscheduled maintenance activities, tracking documentation and creating workflows to maximize facility uptime, throughput, and run rates.

Meet Compliance Standards

  • Document Repository: Store and track versions of critical materials such as supplier documentation, work instructions, quality & compliance documents, etc. Associate them with critical programs for easier audit management.

  • EHS: Manage a wide variety of environmental health & safety programs, and create workflows to support both internal and external standards and audits. Inform preparation of Emergency Response Plans and Safety Data Sheets.

  • Compliance & Audit Management: Ensure suppliers, personnel, processes, and finished goods are in compliance throughout receiving, production, and pre-shipment. Simplify third-party audits by providing secure auditor access to specific information and CAPA records for EPA, FDA, OSHA, and more. 

Integrate Data For Maximized Efficiency

  • Automated (IoT) Data Capture : Automate data capture from manufacturing equipment to support critical quality and production needs, such as temperature monitoring, batch consistency, and chemical composition analysis.

  • Maintenance: Monitor expensive equipment in real-time and leverage data to support Total Effective Equipment Performance (TEEP).

  • Traceability: Quickly unify and associate data and identifiers (such as raw material, batch/lot numbers, etc.) with any process documented by your team during the production cycle.

  • Data Downloads: Easily export and share captured quality and compliance data with customers.

  • API Library: Exchange data with ERP and MES solutions through flexible APIs that can be coded to various use cases, and ensure consistent data across the plant.

  • Inductive Automation (Ignition): Enable machine data captured by Ignition to drive actions within the SafetyChain platform, automating essential plant processes such as quality checks and live OEE monitoring.

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"I would recommend SafetyChain because it helped us take our performance to the next level ... if you really want to know how your plant is operating you need SafetyChain."
Christopher D.
Food Safety & Quality Manager
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"Moving forward with SafetyChain is the right thing to do for your company, brand, customers, and associates. It will make your jobs easier."
Kyle B.
SVP, Operations
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"SafetyChain has allowed us to become data analysts instead of data collectors. Looking at data 3 weeks later does you no good!"
Anita C.
Director of Food Safety & Quality

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