Following our team’s detailed audit and review, the client chose to relocate to a more modern facility and expand their personnel.
The Challenge
A leading general contractor in the water and wastewater construction industry entered a new market area by purchasing a niche manufacturer of a unique repair coating. The new owner lacked experience in manufacturing formulated materials but was extremely conscientious regarding both EH&S and a structured approach to manufacturing.
The existing staff struggled to meet the more stringent policies required by new management, who, in turn, asked ChemQuest to audit the acquired location and its operations.
Manufacturing Process Audit Customized to Client Needs
Our team assessed three main areas during this project: manufacturing operations, including personnel; environmental health and safety (EH&S); and supply chain.
Assessed Manufacturing
Operations
- Reviewed operations for robustness, areas of improved efficiencies, and preventative maintenance
- Determined overall equipment effectiveness (OEE) and known bottlenecks
- Performed CapEx overview regarding routine maintenance and anticipated requirements to meet growth in chemistry or capacity expansion
Conducted EH&S
Diligence
- Reviewed documentation and compliance of OSHA and Process Safety Management, emergency response, PPE/respiratory policies, hazard communication, near-miss rates, and reporting
Assessed Supply Chain
Robustness
- Analyzed key raw material inputs and pricing, including quantities, frequency, and modes
- Conducted material resource planning, including inventory flow, turns, controls, and potential savings
The Results
ChemQuest discovered several lacking standard industry practices that could improve accountability and traceability, especially considering product warranty liability concerns. The team noted numerous limitations regarding the current site location, finding that the limitations were severe enough to hamper the growth potential of the client’s investment. We further provided recommendations for improvements in all audited areas.