Download PDF
Cabot Improves Quality by 30% and Reduces Variability With Global Manufacturing Execution System
Technology Category
- Functional Applications - Manufacturing Execution Systems (MES)
Applicable Industries
- Chemicals
Applicable Functions
- Discrete Manufacturing
- Quality Assurance
Use Cases
- Manufacturing System Automation
Services
- System Integration
The Challenge
Cabot, a global specialty chemicals company, operates 39 manufacturing plants across 19 countries. The globalization of Cabot’s business posed a significant challenge for the manufacturing function. Independent site-based groups needed to transform into an integrated global organization. Access to information from different sources — including manufacturing, the supply chain and financial systems — was vital to make better, faster business decisions. An MES could help with the transformation by integrating and visualizing information across the enterprise. To help overcome the challenge and realize the business potential, Cabot launched an MES visioning process to define the direction and business advantages for their manufacturing systems.
About The Customer
Cabot is a global specialty chemicals company that operates 39 manufacturing plants across 19 countries. The company is committed to delivering high-quality products and maintaining manufacturing excellence, which are key to its business success. As the company globalized, it saw opportunities for improvement, including sharing production recipes and providing visibility of production metrics across sites. However, this required rapid and accurate integration of global manufacturing data with their enterprise systems. To facilitate better decisions, Cabot needed a robust manufacturing execution system (MES) to drive improved product quality.
The Solution
Cabot standardized on Aspen InfoPlus.21 as its MES across all 39 manufacturing sites. The solution’s flexibility, level of integration and services-oriented architecture are key to successful enterprise-wide deployment and the ability to share data and applications. Aspen InfoPlus.21 allowed Cabot to implement the solution to their specific business context and standardize on a common structure for every site. An important aspect of Cabot’s solution was the ability to roll up site information across the enterprise to top-level corporate views, facilitating the sharing of best practices across all sites. Over time, Cabot has used its MES foundation to create an enterprise performance management network across their plants. The network has grown to include AspenTech advanced process control and production scheduling solutions and additional applications involving recipe management, grade changes, emissions reporting, dryer controls, manufacturing process compliance, product and process metrics, lab data and ERP systems.
Operational Impact
Quantitative Benefit
Related Case Studies.
Case Study
Honeywell - Tata Chemicals Improves Data Accessibility with OneWireless
Tata was facing data accessibility challenges in the cement plant control room tapping signals from remote process control areas and other distant locations, including the gas scrubber. Tata needed a wireless solution to extend its control network securely to remote locations that would also provide seamless communication with existing control applications.
Case Study
Advanced Elastomer Systems Upgrades Production
In order to maintain its share of the international market for thermoplastic elastomers AES recently expanded its Florida plant by adding a new production line. While the existing lines were operating satisfactorily using a PROVOX distributed control system with traditional analog I/O, AES wanted advanced technology on the new line for greater economy, efficiency, and reliability. AES officials were anxious to get this line into production to meet incoming orders, but two hurricanes slowed construction.
Case Study
Wireless GPS Tracking & Security Monitoring
Enhancing the security of hazardous freight and ensuring compliance with Homeland Security’s Transportation Security Administration mandate that all trains carrying chemicals capable of creating a toxic inhalation condition are equipped with on-board safety monitoring systems.
Case Study
Field Device Asset Management For Chemical Company in China
Chinese chemical subsidiary of multinational corporation serves customers throughout the world. Sales offices and research and technology centers are strategically located to provide rapid response to customer requests. Just two workers were assigned to maintain thousands of intelligent instruments in three production units, so they could do little more than react to device issues as they appeared. This costly maintenance method inevitably led to unexpected downtime when a critical instrument failed. Plant management recognized the need to change from reactive to predictive maintenance for all assets, including instruments and control valves, but help was needed in implementing such a technology-based initiative.
Case Study
Industrial Workforce Mobility for Improved Safety & Operations
Huntsman Corporation, a global manufacturer and marketer of differentiated chemicals, undertook an aggressive program to eliminate injuries, product defects, and environmental releases at their Port Neches facility. Termed “Project Zero”, this program required a completely mobile solution to empower operations and maintenance personnel to capture defects, track work progress and make process and safety related decisions in real-time.
