What will be the future chemical factory director like? You can't imagine

Introduction: In 2020, the Chairman of China Sinochem named China Sinochem's digital strategy "Online Sinochem", clarifying the direction of "Online Sinochem, Digital Sinochem, and Intelligent Sinochem". Digitalization has become a key production factor in the development of Sinochem in China, and is driving profound changes in the development mode and production mode of enterprises.

Through intelligent computing, equipment failures can be predicted in advance and preventive measures can be taken; Through remote diagnosis, even though separated by thousands of miles, it is still possible to accurately determine and eliminate the risk of parking production devices... In China Sinochem, when production and manufacturing enterprises are "tied up" with digital technology, these seemingly sci-fi "factory of the future" scenarios are becoming reality one by one.

In today's world, a new round of technological and industrial revolution is booming, and digital technology is developing rapidly. In the process of building a powerful network country and a digital China, whether an enterprise can seize the opportunities given by industrial digitization and digital industrialization, and generate new development momentum through technological innovation and digital transformation determines whether it can win the first chance in future development.

In 2020, the directors of China Sinochem named China Sinochem's digital strategy "Online Sinochem", clarifying the direction of "Online Sinochem, Digital Sinochem, and Intelligent Sinochem". Digitalization has become a key production factor in the development of Sinochem in China, and is driving profound changes in the development mode and production mode of enterprises.

So, what is the magic of "digital factory"?

Saint Austrian Chemistry

——

Digital rate of improvement

Big data driven decision-making

SINORGCHEM is a global comprehensive service provider of polymer additives, covering more than 50 countries and regions worldwide. San'ao Chemical proposes a strategic transformation goal of digitalization, intelligence, and service with the construction of "Smart Sennics" as the core, integrating digital thinking into all aspects of the enterprise.

Since 2017, the company has started the construction of digital chemical plants, and has successively completed the construction and implementation of MES systems, equipment management systems, HSE systems, and WMS systems. It has created a digital operation management platform covering the entire business chain at the factory level, standardized the factory operation management process, and improved the overall operational efficiency.

case

The Taian factory of Shengao Chemical Co., Ltd. saves 50 hours of labor in terms of production statistics every day, reduces the waiting time for each incoming and outgoing business by 1.3 hours, and conservatively estimates the energy saving at 200000 yuan per year. The Equipment Section has combined the use of digital systems with organizational structure optimization, reducing the number of equipment staff from 18 to 5.

After the popularization of digital applications at the grassroots level in factories, SINORGCHEM began to further try a data-driven work model, which combines objective data and empirical knowledge to provide real-time feedback and suggestions for the production management of the factory's frontline, helping the factory achieve further improvements in safety, quality, and cost.

case

Through the implementation of the CPM system, a working mechanism for PID loop evaluation and optimization has been established, with the automatic control utilization rate increased from 40% to 95%, and the loop excellence rate increased from 60% to 75%, greatly improving the overall production process smoothness. Through the construction of a remote diagnosis platform for equipment, intelligent algorithms can be used to detect and judge the precursors of equipment failures, support expert remote diagnosis, and significantly reduce unplanned parking and production losses caused by unexpected equipment failures.

Sinochem Blue Sky

——

Combination of soft and hard

Create a new digital business format

Sinochem Lantian is a leading enterprise in China's fluorine chemical industry, with products widely used in more than 20 fields such as automobiles, household appliances, and new energy, and multiple varieties with domestic/global market share.

case

The automated filling production line for industrial robots and visual monitoring technology in the fluoride industry jointly developed by Sinochem Blue Sky and robot manufacturers has seen a decrease in the number of workers by more than 65% and a production efficiency increase of more than twice since its launch. After preparing a production plan in the production execution system (MES), the plan dispatcher reaches the production line. After the product is offline, it scans the code to store, issue, and ship the product. The work is coordinated, orderly, accurate, and fast, greatly solving the employment problem and the timeliness of order delivery.

Automation transformation and upgrading, as well as technical transformation of instrument and equipment at the device level, and PID circuit tuning, are "hard" parts in the construction of Sinochem Blue Sky Intelligent Factory. In terms of soft power, Sinochem Blue Sky has built a value chain management information system from supplier management to customer management at the operational level, achieving seamless docking and business collaboration between upstream and downstream suppliers, enterprises, distributors, and end customers.

Nantong Xingchen

——

Let data act as a safety "supervisor"

Guarantee device "safe, stable, long-term and excellent"

Nantong Xingchen is a "Double Hundred Action" enterprise of the SASAC. It has multiple sets of large-scale chemical production units with a total production capacity of over 400000 tons and an annual sales revenue of nearly 5 billion yuan.

case

Nantong Xingchen has comprehensively deployed and applied the SAP-ERP system to achieve comprehensive management, production, marketing, supply chain, and other production and operation coverage. Through business and system optimization, the "three streams in one" basic management and marketing management have been improved; Build a digital intelligent warehouse, deploy systems such as vehicle reservation, unattended weighbridge, and warehouse management system (WMS), and integrate with ERP, e-commerce, manufacturing execution system (MES, under construction), and supplier relationship management (SRM) systems to improve the intelligent level of warehousing and logistics.

In terms of HSE digitization, Nantong Xingchen has completed the construction of a "Five in One" safety management platform, and launched more than ten functional modules in five major systems, including major hazard source monitoring and early warning, and flammable/toxic gas monitoring and alarm, realizing the transformation from safety management to informatization.

In terms of production digitization, Nantong Xingchen uses near-infrared and APC advanced control and modular monitoring as the starting points, comprehensively perceiving the health status of each production line, and through precise control, achieving production optimization, cost reduction, and efficiency enhancement.

In Nantong Xingchen's marketing work, digital applications have also been fully reflected. The company has strengthened lead analysis, established a node management and LTC (Lead To Cash) process framework from market to customer, and accurately screened and found valuable customers.

"After the new production line goes online, our place has become a popular online punch point," said Yan Junhui, director of the fifth workshop of Sinochem Lantian Shaanxi Base, with pride in his words. Over the past few years, he has clearly felt that front-line workers are no longer "screws" engaged in manual work. Factories are becoming increasingly advanced and equipment is becoming increasingly intelligent. Yan Junhui and his colleagues have gradually improved their skills and thinking during the learning and operation of new equipment, achieving personal improvement and leapfrogging.

The story and changes of a person named "Yan Junhui" reflect the dynamic development prospects of the traditional chemical industry. In the tide of digital transformation, Sinochem will seize the opportunity, reshape organizational relationships and production and operation methods, and generate new development momentum through innovation and change, so as to win the winning opportunity for the enterprise's future development.