Operational Excellence Model for Formaldehyde and resins Plant Catalog.

1. Improving plant performance through
Operational Excellence
Formaldehyde industries

2. If you’re in the formaldehyde industries
you need the right strategy
Formaldehyde plants
Formaldehyde is the most commercially important aldehyde. Urea-, phenol-
and melamine-formaldehyde resins (UF, PF and MF resins) accounted for
approximately 63% of world demand. Formaldehyde is a basic building block to
many important industries, it is used to manufacture resins; as an intermediate
for synthesizing other chemicals and is also directly used without further
processing. Over 50% of consumption accounts on construction/remodeling
activity, and to a lesser degree, the automotive industry.
World consumption is forecast to grow at an average annual rate of 4.0%
during 2009–2014. Demand for these markets is greatly influenced by general
economic conditions. As a result, demand for formaldehyde largely follows the
patterns of the leading world economies.
The Today, all of the world's commercial formaldehyde is manufactured from
methanol and air using either a silver catalyst or a metal oxide catalyst. The
silver catalyst process that combines dehydrogenation and oxidation to obtain
formaldehyde is used by this end user with 100 TPD plant capacity. Most
formaldehyde producers are concerned primarily with satisfying captive
requirements for derivatives and/or supplying local merchant sales.
Major Challenges & Opportunities Formaldehyde is usually produced close to the point of consumption since it is
fairly easy to make, is costly to transport and can develop problems associated
 Volatile Methanol price.
with stability during transport. As a result, world trade in formaldehyde is
 Utilizing Maximum plant efficiency. minimal day by day.
 Environmental Issues and air pollution.
 Lower Methanol yield.
Be prepare for Future
 Higher Energy Consumption.
 Higher Start up time.
 Consistency in final product.
Performance Improvement through OE
 Lack of awareness among employee
towards uses of Chemicals.
Operational excellence model helps achieve business goals while lowering
 Shortage of Skilled Manpower in costs and improving cycle times. It standardizes processes and integrates
Operation Process such as Engineering operations across multiple channels of supply and distribution, supporting
and Production. high-volume, low-margin business strategies
The Mattcons consulting team assists its clients to increase the value of their
corporation, division, or individual facilities. Our consultants are focused
formaldehyde specialists and have developed cutting edge methodologies for
the analysis and integration of business solutions that withstand market cycles,
and aims to maximize the enterprise value to the shareholder.

3. Mattcons approach towards
Operational Excellence.
Value Proposition
Increasing Profitability and Cash Flow
Mattcons strategies, tools and techniques and our methodologies designed for
improving business performance, improve equipment uptime (OEE), reduce scrap,
Our Expertise improve yield, improve quality & productivity, accelerate set-up/change-over times,
reduce lead times, optimize inventory.
At Mattcons We look beyond cost
management and focus on maximizing Driving Culture Change
the income-generating potential of
employed capital. Our Consultants have Companies who successfully leverage operational excellence as part of a strategic
deep experience helping clients achieve platform for growth often achieve market performance well beyond their nearest
and accelerate growth in their core competitors. We can help you how to expand continuous improvement into non-
business and beyond. Combining manufacturing areas, how to enhance sales force productivity, how to optimize the
creativity and analytical insight with maintenance activities and enforcing the employees in all level.
client engagement, our approach helps
Supporting Growth Initiatives and New product development
clients overcome both external and
internal barriers to growth. We will share best practices for applying process excellence to new product
development and commercialization, Efficient product development processes closely
integrated with the operational processes . You will gain important advantages, such as
reduced lead time to market, improved quality and increased development capacity.
Key Results Beyond the Basics
 Reduce Manufacturing Cost by 20 % Many manufacturing organizations need to expand continuous improvement
 Number of Breakdown reduced by 50% throughout the enterprise and seek training to expand capabilities into marketing,
 OEE improved by 30 % customer service, engineering ,new product development and quality control.
 Customer Complain down by 60%
Supply Chain Management : The Real Improvement
 Inventory down by 30%
Major Accidents reduced by 80% The complex and often costly internal supply chain processes is one area that many
Improvement of Suggestion 10 times businesses seek to improve. By “killing complexity” in the overall supply chain system,
 Improve 5S score by 80% companies will experience better, faster delivery with lower costs .
Reduce Energy Consumption by 20%
Consistency in final product by 60% Focus on Maintenance : Key for enhancing Profitability .
Proper maintenance of plant equipment can significantly reduce the overall operating
cost, while boosting the productivity of the plant. Hence another perspective of looking
at maintenance function is not only to maintain but also to enhance the process or the
plant operation system as a result of turnaround planning.
Methodologies
TPM, 5S and SMED It is a program
 Lean Manufacturing that is more than just worthwhile.
 Value Chain and Value added analysis
 Management System
Strategic Alignment Return Over Investment (ROI)
 RCM and TQM
10 to 33+ Folds of investment in Consulting fees.

4. Pick our brains before
Making your next move. E-mail : dsahoo@mattcons.com
If you are interested in scheduling a
no obligation 30 minute consultation to Phone : +91 - 902.900.5850
discuss any performance improvement.
please contact:
More About Mattcons
MATTCONS Offering’s
"We partner with clients in all
sectors and regions to identify Management Consulting
their highest-value opportunities, Lean Manufacturing Total Quality Management
address their most critical Reliabity centered Maintenance Supply Chain Management
challenges, and transform their  Total Quality Management Operational Excellence
businesses. Our winning  ISO Series Total Productive Maintenance.
combination of local know-how,
international orientation and Technical Consulting
customized approach ensures that Vibration Analysis Motor Current Analysis
our clients achieve sustainable IR - Thermography NDT techniques
competitive advantage, build more Wear debris analysis Rotor balancing
capable organizations, and secure
lasting results. We seek to be Green Consulting
agents of change—for our clients, Carbon Risk Management Carbon Pricing
our people, and society broadly” Carbon Fund Management Carbon Neutrality
Carbon Portfolio Valuation Carbon Rating (MATCARATS)
Training and Certification Courses
Public Seminar and Workshop Organization Development
On -site Training (OST) Change Management
On Job Training (OJT) Online Certification Courses
Process improvement Certification Courses
Projects
Project Management Technical Support
Pre project Engineering Services Decommissioning
Contact Us Engineering Services Environmental services
Construction and Field services
+91-22-412-36302
Maintenance Products
askus@mattcons.com
CMMS - Computerized Maintenance management software .
www.mattcons.com
Operation Outsourcing
 Operation Outsourcing
 Manufacturing Outsourcing
Mattcons Services Private Limited.
Waghbill Naka, GB Road, Thane (West), Mumbai - 400607
Regd. Office – Kalyan Nagar, Pallahat, Khurda, Orissa, India – 752055