26K
Employees worldwide
Refreshed and Deployed Standard Work Processes for a Global Industrial Chemical Company
A global chemical manufacturing company operating across approximately 35 countries, the company comprises three primary business units. One of its business units operates critical production facilities in the US, producing ethylene, ethylene glycols, propylene and propylene glycol for industrial applications.
Industry: Chemicals
Industry: Private Equity
Service: Cost and Value Engineering
Service: Manufacturing
Service: Operations Strategy and Transformation
Service: People and Organization
Our Client
A global chemical manufacturing company operating across approximately 35 countries, the company comprises three primary business units. One of its divisions operates critical production facilities in two US states, producing ethylene, ethylene glycols, propylene and propylene glycol for industrial applications.
148
Facilities globally
$18.7B
Consolidated revenues
35
Countries covered
“What keeps me up at night is how much institutional knowledge could walk out the door. We do our best to ensure that doesn't happen, and when we can't retain people we try to retain that knowledge. We have systems, but I always wonder what we might be missing.
“
The Challenge
The company needed to futureproof operations while building on the initial success of its cost transformation program. The company was looking to achieve annual run-rate improvements of $450 million USD by 2026, with fixed cost reductions as a core priority.
- Institutional knowledge risk: Critical operational expertise resided with individual workers, creating vulnerability when experienced personnel left the organization
- Maintenance execution gaps: Both acquired sites required enhanced maintenance practices and turnaround management to meet performance targets, while managing highly hazardous materials and processes
- Standardization needs: One site had inherited processes from a prior acquisition that needed to be integrated with best-practice methodologies, while the other required fresh operational frameworks after its 2021 restart
Real Results Achieved Together
The standard work deployment transformed maintenance execution across both sites through systematic process improvements and knowledge transfer. Working alongside the company's in-house teams, we established repeatable, high-performing maintenance practices that delivered immediate and sustainable cost reductions.
$10M
Fixed cost reduction (first year)
-10%
Reduction in fixed costs achieved (first year)
20-30%
Enhanced maintenance compliance
Transformation Impact
- Created a simplified organizational structure with clear roles, responsibilities and accountabilities
- Established efficient and repeatable global standard work processes
- Facilitated a consistent, high-performing approach across both sites
Our Approach
Our engagement began with rapid assessments at each site, followed by five weeks of detailed analysis across both facilities. Over the subsequent 12-14 week period, we developed and deployed refreshed standard work processes using a “train the trainer” approach.
The methodology focused on planning effectiveness, material kitting and schedule compliance, break-in work management and operator-performed maintenance efficiency. We enhanced S4/HANA system utilization, conducted wrench time studies and optimized preventive maintenance programs.
The team developed detailed process maps, work instructions and implementation enablers designed for enterprise-wide deployment. This systematic approach integrated proven best-practice methodologies with existing site capabilities, ensuring sustainable knowledge transfer across the organization.
Related Services
Cost and Value Engineering
Rising costs demand optimization from design through production. We apply cross-functional value engineering, zero-based redesign, and continuous cost tracking to protect margins.
Manufacturing
Aging equipment meets rising costs and technology disruption. We transform operations through smart factory integration, predictive maintenance, and workforce capability building.
Operations Strategy and Transformation
Helping organizations rethink how they create value. We strengthen performance, build resilience, and accelerate growth across every layer of your business.
People and Organization
Workforce transformation, leadership development, and structure optimization. Learn more about our People & Organization consulting services.
Facing Similar Manufacturing Excellence Challenges?
- Struggling with maintenance costs while managing hazardous processes and aging infrastructure
- Seeking to standardize operations across multiple sites for consistent performance
- Ready to transform maintenance execution through proven standard work methodologies
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