The chemical industry landscape is quite diverse in contrast with other manufacturing industries. The main reason being chemical plants mostly deal with hazardous materials and processes and having a fool-proof maintenance of its facilities assumes paramount importance in the wake of implementing an effective maintenance strategy. The ability to access up to data in real-time is critical in mitigating costly and dangerous safety incidents. This blog talks about the critical Challenges in Chemical Industry and how a mobile asset management (EAM) solution can play a major role in mitigating such challenges.
Overview:
Chemical Industry Landscape – Current Challenges
Crafting and implementing the right maintenance strategy is an herculin task for chemical plants, particularly in the wake of dynamic market demands and rising customer expectations. Some of the critical Challenges in Chemical Industry plagued by this industry include utilization of critical assets in dangerous conditions, keeping pace with environmental, health and safety compliances, workforce preferences and conflict between safety and productivity.
With demanding work culture and high stress on chemical machinery, priorities are shifting towards adopting an efficient maintenance process. Companies are slowly learning to shed their traditional processes that lead to wastage of resources, apart from running the risk of unplanned downtime of their equipment.
Typical Challenges of Paper-Based Processes
Though companies are slowly shifting their mindsets towards a more proactive, digital transformation strategies, however, still a major chunk of companies are still relying on manual, paper-based processes, hampering data integrity, production processes or even struggling with outdated maintenance practices. Some of the challenges include:
- Lack of real-time visibility
- Improper resource utilization
- Meagre response times
- Zero tracking capability
- Delays in communication
- Data discrepancies and errors
- Change Management
Key strategies to overcome Challenges in Chemical Industry
- Implement robust maintenance programs: Regular maintenance is crucial for ensuring the reliability and longevity of assets in the chemical industry. Implementing preventive and predictive maintenance programs can help identify and address issues before they escalate into costly breakdowns.
- Utilize advanced monitoring and diagnostic technologies: Leveraging technologies such as IoT sensors, predictive analytics, and machine learning can provide real-time insights into asset performance and health. These tools enable early detection of potential issues, allowing for proactive maintenance and minimizing downtime.
- Prioritize safety and compliance: Safety is paramount in the chemical industry due to the hazardous nature of substances involved. Implementing rigorous safety protocols and ensuring compliance with industry regulations is essential for protecting both personnel and assets.
- Invest in employee training and development: Proper training is essential for employees to operate and maintain assets safely and efficiently. Providing ongoing training and development opportunities ensures that staff members are equipped with the knowledge and skills needed to effectively manage assets.
- Optimize inventory management: Chemical plants often deal with a wide range of raw materials and products, requiring efficient inventory management systems. Implementing technologies such as RFID tagging and inventory optimization software can help minimize waste, reduce costs, and ensure timely availability of materials.
- Embrace digitization and automation: Digital transformation and automation can streamline asset management processes by centralizing data, improving visibility, and enabling remote monitoring and control. Investing in digital solutions can enhance operational efficiency and agility while reducing manual errors.
- Foster a culture of continuous improvement: Encourage employees to identify areas for improvement and implement innovative solutions. Establishing a culture of continuous improvement fosters innovation, increases efficiency, and helps adapt to evolving industry trends and Challenges in Chemical Industry.
Role of Mobile Solutions in Effective Plant Maintenance
The strategies outlined above highlight the significance of technology in improving the asset management culture in a chemical industry. Leveraging technologies like barcode scanning, IoT, artificial intelligence (AI) or GPS can create a long-lasting impact on the way assets are managed or maintained, while empowering the workforce to take quick, reliable decisions.
Organizations that leverage ERP systems like Oracle Plant Maintenance or SAP S/4 HANA have an edge over others, who solely rely on manual processes. An efficient ERP system can help streamline the operational processes of asset management, while ensuring high level data safety and integrity.
However, exclusively relying on desktop systems may not serve the purpose, particularly for workers who deal with hazardous machinery remotely. To cater to such workforce and to supplement an existing ERP system, a good mobile EAM solution is the need of the hour. A solution that leverages the latest technologies such as AI, GPS, barcode scanning and more can make a huge difference in seamless data access, quick asset tracking or predicting maintenance schedules beforehand.
From the above backdrop, Propel Apps’ mobile EAM solution perfectly fits the bill, providing the much-needed solace for remote workers, who are looking for a perfect solution that is intuitive, user-friendly, works offline and above all cost-effective. Propel Apps’ EAM solution leverages the power of Oracle Maintenance Cloud or SAP S/4 HANA in ensuring that your workforce always has access to the latest data, offering a seamless and stress-free asset management experience.
To know how Propel Apps’ EAM solution can make a huge difference in your chemical industry in improving the overall asset management experience, schedule a call with us today.
