Productivity Challenges in and Way Forward for Chemical Industry

AT A GLANCE

Agility is a synonym for growth in today’s business environment, and chemical companies are continually attempting to be agile in processes, operations, and outcome to keep up with the changing times.

Conventionally, many chemical companies have adopted the reactive model, which is now adversely affecting their overall productivity and market responsiveness.

Adapting newer technologies to leverage the maximum out of the infrastructure and fortifying their IT network is essential for chemical companies to improve their output.

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Today, the chemical sector has entered a phase of adoption: adapting newer technologies, transformative business models, and more. These changing times create excitement and uncertainty amongst the chemical companies who are continually looking to enhance their market share by driving productivity. While many chemical companies have invested heavily in better, newer IT infrastructure, they have not succeeded in leveraging this infrastructure to its maximum potential. On the other hand, other companies are still wary of going the digital way, creating uncertainty among decision-makers in chemical companies.

According to PWC’s 23rd Annual Global CEO Survey, 33% of chemicals CEOs are not very confident about their company’s prospects for revenue growth in the next 12 months.

It is evident that chemical companies are facing challenges when it comes to improving productivity and growth rate. By looking at how chemical companies can overcome these uncertainties, one would first need to comb through the chemical industry pain points when it comes to driving productivity.

The Chemical Industry Challenges in Improving Productivity:

1.The Steep Fall in Oil Prices:[/b]Commodities prices are the catalysts in deciding the outcome rates of the chemical companies. The year 2020 saw an unprecedented decrease in oil prices, causing chemical companies across the USA and the globe to suffer low productivity rates. The soft commodities prices have also caused a massive imbalance in the raw material’s demand patterns, resulting in a disrupted product lifecycle for many chemical companies. Outcomes are getting hit across the board due to affected oil prices.

2.Difficulties in Adapting to Newer Technologies:[/b]Adapting newer technologies and tools is not only a smart move but an inevitable one for the chemical companies. The need of the hour to build a robust IT infrastructure can generate and analyze data, automate operations, and streamline the supply chain. However, many chemical companies are still not at an advanced stage of going digital and cannot make use of the latest technologies. Lack of skilled, knowledgeable professionals and consultants also leads to often misguided judgments, causing productivity to take a hit.

3.Lack of Real-time Visibility to Different Stakeholders:[/b]Chemical companies involve multiple stakeholders, many of whom are geographically separated. The production process involves changes, call-backs, and unexpected challenges at any point in the chemical product’s lifecycle. However, with legacy systems and reliance on manual intervention, there is a lack of transparency and complete visibility to all the stakeholders involved – leading to process delays, communication gaps, and operational glitches. All these negatively impact the rate of productivity.

4.The Snowball Effect of Covid-19 Pandemic:[/b]The COVID-19 pandemic has challenged the business outlooks for the year 2020 in the first quarter itself. Borders had to be closed, transportation had to halt, travel stopped, and plants shut. Supply chains globally were disrupted; operations across chemical plants either slowed down or stopped. The slowdown had a massive effect on the productivity in the chemical sector. Even as the world is slowly starting to open up again, there are still skeletal workforce issues, lack of investments, and demand discrepancies that will continue to haunt the chemical companies.

FIGURE 1:How Modern ERP Systems Enable Better Productivity

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The Way Ahead: Overcoming the Chemical Industry Challenges with Digitization​


The chemical companies need to embrace technology to keep up with the changing times. Opting for data analytics and automation will streamline challenges in operations management and help maneuver efforts to increase productivity. A healthy IT infrastructure with robust enterprise resource planning (ERP) and management capabilities such as the Microsoft Dynamics 365 Finance and Operations can serve as the one-stop solution for various chemical company challenges.

FIGURE 2:ERP in Chemical Industry: The Benefits

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Microsoft Dynamics 365 ERP helps in keeping track of the budget, managing changing prices and adjusting actuals accordingly, collating and analyzing data from chemical plants and top floor, and many such enterprise management functions. Your chemical company will have a systematic tool that keeps track of orders, bill of material, production processes, supply chain, booking, and revenue that helps immensely in anticipating plausible glitches and avoiding them with proactive measures.

There is no doubt that chemical companies will thrive with the adoption and utilization of technology in its prime. The decision-makers in these companies can bring transformation and enhance productivity by investing in the future and making the right choices of welcoming the change.

Key Takeaways:​


Changing times call for change in attitude, and the chemical companies will need to integrate this change in every facet of product development to be effectively market-responsive

With a robust ERP system and other cutting-edge technologies, the chemical companies can plan and act upon increasing their outcome rate.

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The article discusses the pressing need for chemical companies to embrace agility and adopt newer technologies to overcome conventional reactive models and drive productivity. It highlights key challenges faced by the industry and proposes technological solutions, particularly emphasizing the role of Enterprise Resource Planning (ERP) systems like Microsoft Dynamics 365.

Agility as a Growth Driver: The piece opens by stating that agility is synonymous with growth in today's business environment, and chemical companies are actively seeking to integrate this into their processes, operations, and outcomes. This is a critical shift from their "conventionally adopted reactive model," which is now negatively impacting their "overall productivity and market responsiveness."

The Need for Digital Transformation: The chemical sector is in a phase of significant change, involving the adoption of "newer technologies, transformative business models, and more." Despite heavy investments in IT infrastructure by some, the full potential of these investments often goes unleveraged. Conversely, other companies remain hesitant to "go digital," creating uncertainty among decision-makers. This hesitation is reflected in PwC's 23rd Annual Global CEO Survey, which revealed that "33% of chemicals CEOs are not very confident about their company’s prospects for revenue growth in the next 12 months." (It's worth noting that more recent PwC surveys, like the 28th Annual Global CEO Survey, might show updated confidence levels, but the core challenge of uncertainty and the need for reinvention remains a key theme for CEOs across industries).

Key Challenges to Productivity: The article identifies four major pain points hindering productivity in the chemical industry:

  1. The Steep Fall in Oil Prices: Oil prices are "catalysts in deciding the outcome rates." The "unprecedented decrease in oil prices" in 2020 (likely referring to the significant drop during the initial phase of the COVID-19 pandemic) caused "low productivity rates" globally. This volatility also led to "massive imbalance in the raw material’s demand patterns," disrupting product lifecycles.
  2. Difficulties in Adapting to Newer Technologies: Building "robust IT infrastructure" capable of data generation, analysis, operation automation, and supply chain streamlining is "inevitable." However, many chemical companies are not yet "at an advanced stage of going digital," often due to a "lack of skilled, knowledgeable professionals and consultants," leading to "misguided judgments" and productivity hits. This is corroborated by Accenture's findings, which suggest that technology alone isn't a silver bullet; successful digital transformation requires simultaneous adjustments to work processes, roles, and training strategies.
  3. Lack of Real-time Visibility to Different Stakeholders: The complex, multi-stakeholder nature of chemical production, often with geographically separated teams, leads to challenges. "Legacy systems and reliance on manual intervention" result in "lack of transparency and complete visibility," causing "process delays, communication gaps, and operational glitches" that negatively impact productivity. Enhanced supply chain visibility through digital solutions, IoT sensors, and AI platforms is crucial for the chemical industry, as highlighted by various logistics and technology providers.
  4. The Snowball Effect of Covid-19 Pandemic: The pandemic significantly disrupted the chemical sector in 2020. Border closures, transportation halts, and plant shutdowns led to "disrupted supply chains" and slowed or halted operations. Even with the world reopening, "skeletal workforce issues, lack of investments, and demand discrepancies" continue to affect chemical companies.
The Role of Microsoft Dynamics 365 ERP: The article presents Microsoft Dynamics 365 ERP as a comprehensive solution to these challenges. It can help chemical companies "keep track of the budget, managing changing prices and adjusting actuals accordingly, collating and analyzing data from chemical plants and top floor," and perform various other "enterprise management functions." Specifically, it offers a systematic tool for tracking orders, bill of materials, production processes, supply chain, booking, and revenue, enabling anticipation and proactive avoidance of glitches. It specifically helps with batch production management, regulatory compliance automation, lot traceability, quality control, inventory optimization, and financial costing, offering real-time data access and AI-powered insights.

Conclusion and Key Takeaways: The article concludes with the strong assertion that chemical companies "will thrive with the adoption and utilization of technology." Decision-makers must embrace this transformation by "investing in the future and making the right choices." The key takeaways reiterate that adapting to changing times requires a change in attitude and the integration of technology into every aspect of product development to achieve market responsiveness. A "robust ERP system and other cutting-edge technologies" are essential for planning and increasing outcome rates.
 
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