Increasing Yield & Reducing Energy Losses in an Ammonia Production Plant
- Fertilizer Production
- Mid-sized manufacturer operating a 20-year-old ammonia plant
- North Africa
Standardizing Operations Across Multiple Chemical Production Sites
- Chemicals Manufacturing
- Regional chemical manufacturing company
- Operations standardization across three plants in two countries
Obstacles Our Experts Have Transformed into Opportunities
A regional chemical manufacturing company with three operational sites lacked a unified view of its core processes:
Inconsistent Site Practices
Operational practices varied by site—even for identical equipment and workflows
Missing or Outdated SOPs
SOPs were either outdated, undocumented, or passed through informal on-the-job training
Lengthy Operator Onboarding
Onboarding new operators took 5–6 months due to absence of visual workflows or structured documentation
No Cross-Site Performance View
Shift leaders and managers had no reliable tools for cross-site performance comparison
Audit Findings: No Standardization
Internal audits repeatedly flagged non-standardized procedures and documentation errors
Tribal Knowledge Risk
The organization was scaling fast—but its process knowledge was trapped in people’s heads.
TEEC’s Expert-Led Solution
Our Engineering Consultants activated their Process Clarity & Documentation service to create a centralized, structured, and visual foundation for operations:
What Our Experts Did
Conducted on-site process discovery workshops with subject matter experts and frontline teams
Captured actual workflows using BPMN (Business Process Model & Notation) across operations, maintenance, HSE, and logistics
Developed standard operating procedures (SOPs) with visuals, risk points, and quality checkpoints
Created a centralized digital knowledge base, accessible by plant, role, and language
Designed role-based process accountability charts (RACI) to clarify handoffs and responsibilities
TEEC didn’t just create documents—we built a system to capture, scale, and sustain operational knowledge.
Execution Approach by Teec’s Experts
They structured the engagement into a four-step knowledge-capture and standardization program:
- Conducted on-site workshops at all three facilities with subject matter experts and operators
- Captured existing workflows using BPMN 2.0, noting variations across sites for identical processes
- Identified undocumented activities, handoff points, and bottlenecks across production, maintenance, and QA
- Created visual Standard Operating Procedures (SOPs) and quick-reference job aids
- Documented workflows in both English and Arabic, supported by step-by-step visuals for frontline teams
- Built a centralized Digital Knowledge Portal accessible by plant, role, and process category
- Reviewed documents with frontline users and supervisors to ensure accuracy and practicality
- Standardized naming conventions, version control, and approval workflows across sites
- Ensured all documents aligned with ISO 9001 and internal audit readiness standards
- Conducted train-the-trainer sessions for supervisors and team leads
- Developed a SOP onboarding module for new hires and cross-training use
- Introduced feedback forms and SOP improvement cycles
Results & Impact
Achieved 100% standardization of critical processes across three sites within 90 days
Increased SOP accessibility and usage compliance by 87%, verified via internal audit sampling
Reduced onboarding time for new operators from 5 months to 6 weeks
Reduced procedural errors and deviations during quality audits by 60%
