Customer Profile

Wanhua Chemical Group Co., Ltd. (abbreviated as "Wanhua Chemical") was listed on January 5, 2001 (stock code 600309). Wanhua is the only company in China that possesses mature MDI manufacturing technology and independent intellectual property rights. Its production technology was successfully developed by Wanhua Chemical after years of arduous technological research, making China the fourth country in the world to possess this technology, following Germany, the United States, and Japan.

Project Background

While experiencing rapid development, Wanhua Chemical also faces many puzzles and challenges: management efficiency has reached a bottleneck, equipment comprehensive efficiency is low, technical support from the technology development and management department to the equipment department is insufficient, and the emergency management system is not functioning smoothly. The company has been in a dilemma of "treating the symptoms but not the disease" and has been unable to find suitable solutions. This project is mainly aimed at improving two major difficulties and pain points: operational efficiency and equipment capacity utilization.

Project Process

After five months, the Realscheme project team, together with the project team members from Wanhua Chemical, conducted a comprehensive review of the management process for addressing pain points. The main contents include:

1. Optimize the value chain and business organizational structure of the entire group company, enabling clear matrix diagrams for organizational and resource allocation;

2. Establish an end-to-end process for production and operation management;

3. By reengineering and optimizing processes, we aim to improve management efficiency, enhance authorization, internal control, risk management, and maximize overall efficiency;

4. Establish a set of evaluation criteria system to measure the operational performance of the company, and use quantitative data for effective evaluation;

5. Teach and instruct a set of self driven and self improving management tools and methods to evaluate the performance level of one's own business, identify improvement points and areas.

Implementation results

1. Designed and optimized an organization that matches the forward-looking strategic development of the enterprise;

2. We have initially established a BSC-KPI performance management system based on processes and data;

3. Established a hematopoietic mechanism for processes and trained over ten process experts for the group;

4. Per capita output value increased by 18%;

5. The overall equipment efficiency (OEE) has increased by 12%;

6. The on-time delivery rate has increased by 23%.