Scaling a global production system through capability building and standardization in the chemical industry

Initial Situation

  • An international chemical company had developed a production system and required support to roll it out globally
  • More than 100 sites with different cultures, production processes and standards complicated the rollout
  • Global competition and increasing cost pressure required efficient and standardized production processes
  • The objective was to realize potential through standardization and continuous improvement, reduce costs and capture market opportunities
  • Black, Green, Yellow and White Belts needed to be trained globally

Achievements

0 +
Belts trained
0 M €
Costs reduced through DMAIC projects
0
Production sites transformed to the new production system

Our Approach

  • Set up the rollout of the new production system in waves (three starts per year, approx. 2,000 FTE per wave)
  • Design and implement an individual training program including external certification
  • At each site, train Green Belts (2 per 100 FTE) and Black Belts (0.5 per 100 FTE) for project execution
  • To support implementation, train project teams as Yellow Belts and interested employees as White Belts via e‑learning
  • Embed capability building based on the “see one, do one, teach one” principle
  • Test standards and project approaches locally and apply them globally