Increasing Yield & Reducing Energy Losses in an Ammonia Production Plant
- Fertilizer Production
- Mid-sized manufacturer operating a 20-year-old ammonia plant
- North Africa
Uncovering Efficiency Gaps and Driving Cost Savings in a Polymer Production Plant
- Polymer Manufacturing
- Leading polymer manufacturer
- Performance audit and improvement in a high-throughput polyethylene production facility
Obstacles Our Experts Have Transformed into Opportunities
A major polymer manufacturer operating a high-throughput polyethylene facility had stable production—but rising costs and stagnating productivity:
Rising OPEX Without Output Gains
OPEX had increased by 14% year-over-year, despite flat throughput
No Performance Benchmarking
Performance gaps were difficult to trace due to lack of process performance benchmarks
Inconsistent Operator Execution
Operators were working with outdated SOPs and inconsistent routines across shifts
Repetitive Maintenance Without RCA
Maintenance interventions often repeated the same issues without systemic analysis
Unstructured Internal Improvements
Internal improvement efforts lacked structure, with no cross-functional ownership The plant wasn't broken—but it was leaking value in dozens of small, hidden ways.
TEEC’s Expert-Led Solution
Our Experts deployed its Process Audit & Performance Analysis service to expose hidden inefficiencies and structure a sustainable improvement roadmap:
What Our Experts Did
Conducted full value-stream audits across production, maintenance, and logistics
Mapped actual vs. expected process flows and identified process “drift” areas
Used downtime logs, rework data, and material loss reports to build a loss tree
Benchmarked performance against TEEC’s database of best-in-class polymer operations
Developed a phased improvement roadmap, categorized by quick wins and structural fixes.
This wasn’t just a performance check—it was a forensic, data-informed diagnostic that sparked real transformation.
Execution Approach by Teec’s Experts
They executed a deep-dive audit using its structured Performance Discovery Framework:
- Reviewed 12 months of production, downtime, rework, and quality deviation records
- Mapped performance KPIs (OEE, yield, maintenance compliance) against targets and peer benchmarks
- Conducted cross-functional interviews to surface undocumented pain points
- Performed field-level walkthroughs across production, maintenance, and logistics workflows
- Identified process “drift” areas—where operations deviated from designed workflows or SOPs
- Mapped actual vs. intended process flows and documented critical gaps using TEEC's Loss Tree model
- Used TEEC's Performance Gap Analyzer to quantify efficiency, cost, and quality losses
- Benchmarked against industry best practices in polymers and specialty chemicals
- Facilitated focused RCA sessions with operators, engineers, and planners
- Delivered a phased improvement roadmap ranked by impact-effort matrix
- Assigned cross-functional improvement teams to pilot and scale solutions
- Established a monthly review rhythm and installed KPI dashboards to track execution
Results & Impact
Initiated 6 Kaizen improvement projects based on audit findings
Reduced rework-related quality losses by 23% in 3 months
Identified 12 process inefficiencies that were costing the plant over $850K annually
Reduced cross-functional misalignment with clearly defined handover points
