The Opportunity
BASF has partnered with QualPro on a variety of improvement projects to achieve tens of millions of dollars in accumulated financial benefits. Project goals have included optimizing manufacturing processes, reducing costs, increasing yield, and improving product quality. BASF partnered with QualPro to optimize manufacturing processes and achieve cost savings, without additional capital investment.
Client Impact: Chemical
The Approach
QualPro consultants conducted interviews with project managers and key personnel in order to gain a more thorough understanding of the production process, then proceeded with an advanced statistical analysis to test factors related to production rates and recycling processes. In accordance with QualPro's commitment to driving continuous improvement and fostering a spirit of innovation, consultants worked closely with operators to guide process changes and motivate project team members to exceed their goals. QualPro conducted advanced analysis and experimentation over a period of 4 weeks to identify key changes and make recommendations for improvement.
The Impact
Based on QualPro recommendations, BASF optimized yield and realized annual savings of $2.5 million, as well as increased run times for additional annual savings. Moreover, in combination with subsequent partnerships with QualPro to improve performance, BASF accumulated annual savings of tens of millions of dollars within a four-year period.
BASF Profile
BASF is the worlds largest producer of chemicals and related products, with over 113,000 employees on five continents. At the core of BASF's business strategy is innovation and science, combined with social responsiblity and environmental protection.
"Using QualPro techniques, this team was able to reduce rejects from from 15% to less than 5%. Substandard inventory was reduced to zero, customer complaints were cut 50%, and disposal costs, which last year topped $750,000, were eliminated."
Dr. Michael Hinton
BASF
