Key points
The chemical industry is central to the world’s economy. The industry’s manufacturing processes convert raw materials into more than 70,000 products globally, including fats, rubber, wax, oils, fragrances and flavours.
But, when it comes to manufacturing these integral items, the chemical industry isn’t always adopting the latest innovations to ensure quality levels are maintained to a high standard – and this is a problem. But, it is a problem that is avoidable.
There remains a perception that producing products in high volume is the only way to increase revenue, but this isn’t true – cutting costs, specifically in this instance costs relating to quality levels, is an important tactic. The automotive sector realised this a long time ago and is now a leader in reducing production costs.
Human error is still present in chemical manufacturing, and this window of opportunity for human error remains open wider than it should be. In some instances, data sheet classifications are still completed manually, but when it comes to data sheets, there is very little room for error.
Over-classification can lead to lost sales and excessive costs from shipping, training, and compliance fees. Under-classification may pose safety risks, incorrect occupational risk assessments, and inadequate remediation. Layered Process Audits (LPAs), a key component of automotive quality management, are a sure-fire way to combat this.
How LPAs can help
LPAs are proven to help prevent manufacturing escapes and cut production costs. LPAs involve regular checks of the plant’s manufacturing processes, catching mistakes in a product’s manufacturing process before it is complete. It is, therefore, important that the industry looks at adopting digital LPAs sooner rather than later.
When properly implemented, LPAs are the most effective way to ensure that processes consistently follow approved standards, reducing waste and rework, improving quality, and driving cultural change. Essentially, LPAs ensure that the approved process and formula are followed, with a heavy focus on the human aspect of the manufacturing process.
They also flag any discrepancies before defective products are produced, saving time and money as well as reputation. LPAs are a verification that appropriate controls are in place and a company’s standard process is being followed in accordance with documented requirements.
LPAs are widely used in automotive manufacturing, and they are now finding their way into other sectors at an increasing rate too. This is especially true of the aerospace and consumer products industries. Most frequently, quality leaders from the automotive industry migrate to other sectors and implement LPAs as a best practice at their new organisations, knowing they are a vital tool for increasing productivity and ensuring quality is maintained.
Taking inspiration
The chemical industry can learn a lot from the automotive sector, which has long been a global frontrunner in applying and evolving quality improvement tools. In addition to lean manufacturing processes, the automotive sector has been implementing LPA programmes, in its various evolutionary forms, for more than three decades.
Due to the competitiveness of the sector, automotive companies have always needed to evolve their manufacturing process to maximise quality while minimising costs. Demand for vehicles shows no signs of abating either, at a time when modern safety standards and requirements have never been more stringent. Corners can’t be cut.
Through the adoption of LPAs, the automotive sector has enjoyed several benefits, including:
- Reduction of waste
- Improved cash flow
- Improved product quality and customer satisfaction
- Increased ‘right the first time’ results
- Reduced quality incidents (scrap, rework) and escapes
- Reduced the overall cost of poor quality
LPAs have also allowed the automotive sector to evolve with the times. The chemical industry, for which the stakes are so high, needs to follow the automotive sector’s lead and benefit from the impact LPAs can make. The first steps chemical manufacturers should take to ensure LPA success are:
- Form the LPA team
- Conduct a Failure Modes and Effects Analysis (FMEA) to determine where LPAs are needed
- Identify high-risk trends
- Perform a feasibility assessment
- Readjust and refine the LPA programme to suit requirements
- Begin the development process, using the instructions laid out in the LPA programme
- Test, test and test again until the manufacturing process is perfectly refined
Accelerating success
With the pressure and stakes so high for chemical companies to produce and roll out vital products that are in demand internationally, it is time for manufacturing processes to improve. By following the example of the automotive industry, the chemical industry can take the initial steps to adopting a robust LPA programme and ensure that it can remain a key player in a strong global economy.
