Digital Chemical Industry

With over 90% of everyday products containing chemicals in some manner or the other, the chemical industry becomes one of the most influential and critical sectors in the world today. With growing uncertainty & volatility in a range of end markets, demand for chemicals has become harder to predict. Increasing production flexibility to pursue new opportunities, coupled with improved efficiencies to manage costs, are essential capabilities needed to weather potential storms. Digital technologies offer a path to improve plant capabilities & performance while minimizing costly capital expenditures. Chemical companies also leverage digital to address fluctuations in supply chain and raw material prices.


A new game-changer in the Chemical Industry-Artificial intelligence

Even though the chemical industry is one of the core industries in this post-industrial revolution world, it is marred by various challenges; process optimization is the most significant. This requires a need to address different process inefficiencies, which can be involved in nature. It is also time-consuming and challenging to identify their root causes. All this while trying to adapt to seemingly incessant changes, be it with feedstock prices, workforce demographics, customer expectations, or environmental laws and requirements. With the ever-growing competition, the industry also needs to be always on its toes, innovating regularly to maintain its market leadership.

In the recent past, the digital revolution, together with artificial intelligence and machine learning, has brought about a significant disruption in the chemical industry.

With AIGC AI-based solutions, the chemical companies can use the already available data to measure, model, and implement specific actions to optimize their production line and boost their sales by improving their targeting and bettering their supply chain. With constant analytics and data-based modeling, the industry achieves a more significant success with newer product lines, smart maintenance plans, less unplanned maintenance, and optimized operational costs. Further, with AI-based processes, the industry also improves its production efficiency, reducing their power consumption, while identifying ways to optimize their waste management processes, resulting in reduced carbon footprints.

Featured Solutions & Services from AIGC

Creating a digital transformation will increase the productivity and performance of the industry. We provide end-to-end digital solutions with our digital consulting services, comprising digital strategy consulting, digital architecture designing, and transformation roadmap development. Using emerging technologies, we provide insights into the business, we support companies to innovate and function to become more competitive. To enable competitive advantage and generate growth, we set strategies in motion for clients that unify business and technology architectures. Once we identify the critical business imperatives, we map out initiatives, using information from the data platforms to achieve them.

Significant opportunities are being created by new digital transformation to stay competitive and relevant in business today. Digital Transformation offers new ways to reinvent processes with data, analytics, APIs, machine learning, and other technologies. This results in lowering costs, reducing cycle times, or increasing quality. Adopting technology in process transformation can create significant value. It transforms traditional business models with digital technologies. Today it is easier to convert the plants and factories to smart industries, where no human needs to travel to hazardous locations.

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For achieving progress in this digital era, ‘data’ has become a significant critical asset to an organization today who want to build their transformation models. Be it for improving performance or productivity, AI and Analytics will be the core DNA around which companies need to develop their transformation model. By harnessing the power of analytics, automation, and artificial intelligence (AI), organizations can quickly find a correlation within volumes of data gathered and make informed decisions that can be used across the entire organization.

However, it’s critical to implement the best mix of strategy and technology with a balance of speed, cost, and quality for delivering any measurable business value. As observed by McKinsey, ’50 % of companies that rely heavily on data, embrace AI over the next five to seven years, and have the potential to double their cash flow. By extracting hidden patterns from data, Artificial Intelligence and Machine Learning are playing a critical role in building intelligence. They help make informed decisions, facilitate in reducing human interventions, and lead to enhanced operational efficiencies.

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AIGC Asset Performance Management (APM) by AIGC offers comprehensive implementation of the company’s assets from planning and scheduling to mobility to analytics to asset life cycle management to integrate systems. Powered by advanced analytics and robotics, the predictive forecasting and reliability-centered maintenance help firms enjoy substantial increment in their margins, thanks to the reduced repair and maintenance costs, lower downtime of assets, and fewer critical breakdowns in the production centers. With infrastructure forming the most crucial component of the chemical industry’s production cycle, it is vital to keep track of infrastructure and the workforce’s essential aging. APM by AIGC helps monitor the equipment remotely using data generated by sensors in the assets and continuously analyses the same to improve its operational efficiency and increase the equipment reliability.

APM process improvement, APM package selection, implementation, mobile asset and work management, GIS integration for design, mapping and operation and asset data management, and analytics for condition-based maintenance are critical areas where APM is offered by AIGC can be most effective.

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The Digital Workforce Mobility transforms organizations through- Human-Centered Design. Smart plant operators are enabled by advancements in technologies, including mobile devices, radio-frequency identification (RFID), wearables, analytics, and automated systems to more effectively execute their work. The portable digital workforce platform offers efficiency, control, and predictability built into the plant operations, no matter the workforce’s size. They leverage process and technology applications that help eliminate paperwork, reduce non-productive work, create a safe work environment, automate workflows, and improve efficiencies –ultimately saving money.

For operations, the use of digital tools, wearables, and mobility-enabled solutions helps prioritize, manage, support, and automate high-frequency operator work tasks to transform field operations’ efficiency and safety. Use cases include the creation of configurable forms and checklists, and safety and field audits. For maintenance, digital technology’s workforce connectivity will transform maintenance processes in the field across the asset life-cycle. It’ll do this by using wearables and mobility-enabled solutions to manage and execute tasks such as work orders, in-field asset data management, and workflow improvements between workers, crews, and sites. For capital projects, the combination of workforce connectivity and digital capital projects solutions will enable companies to deliver more excellent value from projects at a higher speed. These benefits will be driven by better control, reduced time to market, minimized budget variances, and improved asset performance. Simultaneously, better management and execution of field construction and commissioning tasks will boost safety and efficiency.

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It is no brainer that higher-performing assets deliver higher results, and improving operational management can help achieve better performance from investments. With manufacturing operations management, AIGC helps maximize production performance, streamline processes and push the operation to save, but productive limits, adopting the model-based approach, bring tangible benefits to the bottom line.

By analyzing data gathered regularly from various sensors across the production line, our experts help build models to help engineers understand how to operate the plant optimally within the asset’s limits. Besides, these models also help reduce energy consumption. It helps improve the quality of products, but it also helps increase the yield from the plants. Other benefits include improving overall plant profitability through automatic detection, control, and correction of operating conditions that may direct costly shutdowns. Our models help engineers avoid ad-hoc manual support methods that cause inefficiencies and time-consuming tasks.

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Industrial revolution 4.0 has helped the industry reduce costs, increase profitability & productivity. Today, the robots and drones perform tasks that were not possible earlier and have pushed uncertainties away from humans. The power of industrial robots is many times more than the leisure market ones. They can now be used not only for loading or unloading in factories but also inside pipelines and confined areas, otherwise difficult for human reach, for repairs.

With the recent advancement of edge computing and connectivity, drones/ aerial robots with AI-on-the-edge capability can perform analytics in-situ and autonomous operations. In hardly accessible uninhabited areas, industrial drones perform tasks such as the inspection of elevated equipment, visual recognition as they have specific features and a piece of special equipment or payload.

By automating the entire surveillance system to help deploy sensor-equipped robots to monitor the air’s contaminants in chemical industries, robotics and drones are slowly taking over many hazardous and challenging tasks in modern plants. By deploying drones and robots by AIGC, we can improve efficiency and automate mundane and repetitive tasks, thereby helping increase the bottom line. From thermal inspections to the monitoring of production lines through real drones to small robots canning entire lines of pipeline and machines for cracks or minor damages, the use of robots and drones can improve the chemical’s efficiency and productivity industry significantly.

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Supply chain forms the backbone of all the manufacturing industries, the chemical industry being no exception to the same. The stable functioning of the supply chain being extraordinarily critical and tricky in nature of a thriving chemical industry operation, AIGC offers services specifically designed keeping in mind the nuances of chemical industry supply chain management. Our services help in infusing efficiency into an already existing supply chain system in the chemical industry. By building digital intervention in various states of the supply chain process,

  • We help capture data points from multiple stages of the process,
  • Analyze and identify key focus areas,
  • Areas that require transformation and help design and implement change in the system, and
  • Bringing in optimization into the process.

Based on the data gathered, we also benefit from design supply chain operations and scheduling, from inventory position management, production management, terminal management to schedule balancing. With data being the backbone of our supply chain optimization process, we have ever-increasing help with data related reporting like inventory optimization, product reconciliation, P&L analysis, risk management, and more. Our services include digital interventions for handling multi-entity complex executions and settlements from detailed analytics to labor-management to even compliance.

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