DSM Cuts Production Losses with SmartPlant®

The Challenge

DSM is a global market leader in more than 60 percent of its markets. DSM's goal is to become more active in the life science market, and it recently announced the acquisition of Roche vitamins and fine chemical division, which is a market leader in this segment. Following the acquisition, DSM employs 27,500 people in more than 40 countries with an annual turnover of US$7.85 billion.

Unplanned downtime is the nemesis of a manufacturing company such as The Netherlands-based DSM, and it is actively engaged in lessening production losses due to unscheduled delays from instrumentation issues.

The Solution

DSM knows it can achieve substantial savings by effectively managing and using engineering design, installation and as-built information, then transforming this information into a valuable strategic asset. In doing so, DSM has recognized savings of 10 to 20 percent in specific areas by using Intergraph SmartPlant® Instrumentation.

By maintaining the sole, accurate and consistent instrumentation database from SmartPlant Instrumentation, DSM lessened production losses due to fewer search and investigation activities for correct information during plant startups, thus shortening plant delays related to instrumentation problems. 

DSM has strong indications that the result is an accumulated operational downtime decrease of up to 0.3 percent per year, which translates into hundreds of thousands or even millions of dollars over a plant's life cycle, depending on throughput, asset utilization and product margin.

With SmartPlant Instrumentation, DSM notes that it has a complete and accurate as-built instrumentation asset available in less than one day after a change is made. This ensures that the as-built status is always up to date for the maintenance crew in case of an upset in the plant shortly after the change.

This benefit is also crucialt with respect to the company’s license to operate. In the event of an incident, authorities require companies to demonstrate that the as-built status fulfilled legislative requirements at that particular moment. For example, within 24 hours of an incident at one plant, DSM was able to generate a CD with the as-built situation, in case of any future inquiry. 

In one of their pharmaceutical plants, engineers have learned that the SmartPlant Instrumentation package better supports validation activities than conventional engineering does.