The "Process Drift" Crisis: Why Traditional OEE Fails the Lab
What is process drift in chemical manufacturing?
Process drift is the gradual deviation of an asset from its optimized operating parameters, leading to "Six Big Losses" such as reduced yield, minor stoppages, and increased scrap that traditional, disconnected OEE systems fail to resolve in real-time.
For Mike (the Tactical Manager), process drift is a nightmare that leads to "Off-Spec" batches.
If a mixing vessel’s motor begins to pull more amperage or slow down by 2%, it might not trigger an ERP alert, but it is already destroying your OEE Performance score.
Fabrico closes this gap by ensuring that any deviation from the "Centerline" results in an immediate, prioritized task for the maintenance team.
Layer 1: Capturing the Truth with Unified Data Intelligence
In a chemical plant, connectivity must be non-invasive and absolute.
Fabrico utilizes the Visibility Trifecta—combining PLC signals, IoT gateways, and Computer Vision—to capture 100% of the operational truth.
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Direct Connectivity: Pull real-time data from reactors, centrifuges, and pumps via PLC or IoT retrofitting.
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Inefficiencies Zoom-In: Use AI-powered cameras to "see" manual interventions or material handling delays that sensors miss.
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Operator Context: Mobile-first interfaces allow operators to log specific batch conditions that impact performance.
This unified dataset ensures that Paula (the Strategic Leader) is managing the Hidden Factory with facts, not assumptions.
Layer 2: Asset Integrity via Condition-Directed Tasks
The "Grease and Guess" era of calendar-based maintenance is a danger to high-value chemical assets.
RCM (Reliability-Centered Maintenance) principles teach us to Preserve Function, which requires moving to Condition-Directed Tasks.
Instead of waiting for a quarterly shutdown, Fabrico uses OEE performance data to trigger maintenance "just-in-time."
When the system detects a performance loss, it triggers a Work Order to Tom (the Technician) with the required SOPs and safety protocols already attached.
This protects the Value Fulcrum, ensuring maintenance effort is applied exactly when it is needed to prevent batch failure.
Comparison Matrix: Chemical Operations Tech Stack
| Feature |
Legacy ERP (SAP/Oracle) |
Standalone OEE Dashboards |
Fabrico (System of Action) |
| Operational Goal |
Financial / Cost Center |
Data Awareness |
Uptime & Integrity |
| Response Trigger |
Manual / Delayed |
Emailed Alert |
Auto-Work Order |
| Root Cause Depth |
None |
Data-Only |
Visual (Zoom-In) Proof |
| Mobile Experience |
Low (Complex) |
Browser-Based |
Field-Ready Native App |
| Planning Logic |
Static |
Manual |
Predictive Availability |
| Implementation |
12-24 Months |
6-9 Months |
3-4 Months |
Layer 3: Predictive Planning for Shutdowns & Turnarounds
For the Strategic Leader, managing a shutdown is the ultimate test of coordination.
Fabrico’s Interactive Planning Board synchronizes with your maintenance backlog and real-time machine health.
This allows Paula to see "Predictive Availability"—knowing exactly which machines are healthy enough for a long batch run and which require immediate intervention.
By aligning the production schedule with the technical reality of the shop floor, you eliminate the "Schedule vs. Reality" conflict that plagues the chemical industry.
It ensures that your Maintenance Cost per Unit is optimized even during high-pressure turnaround periods.
The ROI of a Connected Chemical Plant
For Paula, the business case for Fabrico is built on reclaiming lost revenue without purchasing new reactors.
By stabilizing the process through integrated action, she can increase first-pass yield and reduce the total cost of quality.
As the factory builds its 12-month data layer, it creates the foundation for the Fabrico Agent (AI Roadmap) to begin automating your production flow.
Stop watching your yield drift. Start engineering batch reliability with a System of Action.
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