Case Study 1
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Case Study 1

Optimization of Pulp production, logistics, sales and export Operations

Challenge

WPI operates two pulp production lines at its Ohakune site, where pulp is packed, weighed, quality checked and transported to the train under automated PLC control. Data from this process was needed to:

  • Plant Operations: Simplify production calculations (shift, day, month, year).
  • Marketing & Logistics: Provide online notifications to KiwiRail and the Port of Napier for coordination of transport (trains), warehouse storage and dispatch (ships).
  • Invoicing and Export: Provide digital customs documentation and bill customers on time.
  • Workflow Optimization: Eliminate manual workflows and CSV file transfers that caused inefficiencies and delays, replacing them with digital processes.

Solution

We integrated real-time PLC data with the AVEVA PI system, enabling:

  • Real-time performance management: Detailed production metrics were provided by line, shift, daily and cumulative totals.
  • Customer allocation: Pulp packages were allowed to be allocated to customer orders directly from production operations.
  • Automated integrations: The WPI marketing & logistics system was integrated via APIs with the KiwiRail, Customs and Port of Napier systems, automating the dispatch, logistics, export documentation and invoicing processes.

Results

  • Faster processes: Customs documentation processing time reduced from 1 day to less than 1 hour.
  • Increased accuracy: Better scheduling for transportation logistics (rail and ship) and reduced billing issues.
  • Improved compliance: Better adherence to New Zealand Customs requirements. Increased customer satisfaction: Decreased billing issues and customer complaints

Key Benefits

Real-time integration streamlined processes, reduced manual effort, ensured compliance, optimized logistics, and improved customer satisfaction with faster, more accurate billing and documentation.

Case Study 2

Digital Transformation - New Plymouth District Plan

Challenge

New Plymouth District Council (NPDC) was required to undertake a District Master Plan Review to modernise town planning processes and deliver a Master Plan. Key challenges were:

  • Fragmented Management: District planning information is stored in disparate systems, including electronic files (e.g. text, spreadsheets, GIS maps and PDF files) and paper records, updated manually.
  • Departmental Silos: Information is managed independently by a number of departments with processes that lack coordination and integration.
  • Citizen Experience: Current solutions are time-consuming, prone to data duplication, difficult to maintain and do not meet community needs, such as easy access to planning rules and application tracking.

Solution

NPDC implemented a Digital (end-to-end) District Plan to address these challenges, including:

  • Interactive and Searchable District Plan: Development of a text-based, searchable district Regulatory Plan integrated with spatial GIS maps and relational databases (e.g., UDR and spreadsheets).
  • Unified Digital Platform: Transition from manual updates to a centralized, automated system accessible by all departments.
  • Roadmap to Digitalization: Phased plan creation, beginning with a spatially integrated draft plan by mid-2016 and a fully integrated digital plan by 2017.
  • Community Integration: Enabling citizens to track applications, access planning rules, and communicate with planners through online interfaces.

Results

  • Empowered Community: Citizens gained easy access to relevant planning rules and were able to register and track requests online, improving transparency and communication.
  • Streamlined Processes: Fragmented systems were replaced with a unified digital solution, eliminating manual updates and reducing paperwork.
  • Increased Efficiency: Interdepartmental coordination was improved and data duplication was reduced through synchronized digital systems.
  • Clear Roadmap: Stakeholders and citizens were provided with a phased plan outlining the scope, effort, and timelines for implementing the digital plan.

Key Benefits

The Digital Master Plan modernized NPDC’s planning processes, transforming them into a transparent, citizen-centric system. Increased efficiency, reduced manual work, and improved data accuracy aligned NPDC’s urban planning efforts with community needs, laying the foundation for a sustainable, integrated planning future.

Case Study 3

Fixed Asset Register Consolidation – Manufacturing Sites to HQ

Challenge

Methanex, a global leader in methanol production based in Vancouver, managed Fixed Assets (FBA) processes at multiple plants globally, out of their main ERP.

  • The company relied on spreadsheets and disparate systems that created fragmented workflows.
  • Inconsistent processes and data created compliance risks, including SOX challenges.
  • Inefficient reporting hindered visibility and real-time decision making.

Solution

Methanex migrated existing FBA data from Excel and disparate systems to the company Global ERP, achieving:

  • Centralized Repository: Unified global FBA data for consistent workflows and reporting.
  • Seamless Migration: Ensured data integrity during transition from fragmented systems.
  • Increased Automation: Replaced manual processes with automated workflows to reduce errors and inefficiencies.

Results

  • Improved compliance: Achieved full compliance with SOX and global regulations with robust controls and audit trails.
  • Operational efficiency: Reduced manual errors and streamlined workflows, saving time and resources.
  • Simplified tax management: Ensured accurate depreciation calculations and reporting across all sites jurisdictions, reducing compliance risks.

Key Benefits

Centralizing FBA to the Global ERP ensured SOX compliance, standardized global processes, and supported scalability. Methanex gained real-time data for better decision making, reduced manual errors and risks, and improved efficiency while lowering costs.

Case Study 4

Asset Management Transformation at Methanex Trinidad

Challenge

Methanex Corp. acquired a methanol brownfield plant in Trinidad and Tobago (Titan) and gas rights to build a new plant (Atlas). Key challenges included:

  • Outdated systems: Titan’s ad hoc maintenance system lacked ERP integration and corporate ERP integration.
  • SOX compliance risks: Issues detected by auditors regarding SOX compliance risked publication of notes in the Annual Report.
  • Asset structure gaps: Lack of asset/equipment hierarchy and documentation (Titan).
  • New systems needs: A modern EAMS was required for Atlas, integrated with Company ERP.

Solution

We implemented a comprehensive solution to address these challenges:

  • RFP was issued for experienced EAMS implementers with experience in integration, business analysis, and document management.
  • Project was awarded, user specifications and new business processes were developed.
  • Implemented EAMD (IBM-MAXIMO) integrated with Oracle ERP and Engineering Document Management System (Meridian).
  • Documented asset hierarchy and missing or misplaced data sheets in Titan.
  • Decommissioned the Titan's old ad hoc maintenance system (CMMS).

Results

  • Unified Maintenance System: A single EAMS with standardized maintenance strategies and work plan management.
  • Asset Documentation: Complete documentation of Titan asset hierarchy and data sheets, ensuring operational consistency with Atlas.
  • SOX Compliance: Alignment of financial and accounting processes with corporate standards, complying with SOX requirements
  • Streamlined Operations: Streamlining of maintenance, procurement, purchasing and warehouse processes through the integration of systems (ERP and EAMS).

Key Benefits

Methanex achieved a fully integrated maintenance, engineering documentation and financial systems, ensuring SOX compliance and alignment with corporate standards. IBM-MAXIMO provided consistent maintenance strategies, documented asset data and simplified supply chain operations, improving efficiency and regulatory compliance.

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