Chemicals & Petrochemicals | Perfact Group — Lean Six Sigma and turnaround specialist

Q: How does Lean Six Sigma fit into the chemical industry?

Lean Six Sigma is one of the most proven methods for process improvement in the chemical and petrochemical industries. The combination of Lean (eliminating waste, improving flow) and Six Sigma (reducing variation, ensuring quality) fits seamlessly with the complex, safety-critical processes of a chemical plant. In practice, we use Lean Six Sigma to stabilise production processes, reduce downtime and quality deviations, optimise turnaround preparation and improve maintenance procedures. Our Black Belts and Master Black Belts have in-depth knowledge of the sector — from ATEX environments to SAP PM systems — and speak the language of the shop floor at Chemelot, SABIC and Sitech.

Q: What does Perfact do during a turnaround in the process industry?

A turnaround (TA) is a planned shutdown of an industrial plant for inspection, maintenance and overhaul. Every day of delay costs tens of thousands to hundreds of thousands of euros — effective preparation and execution are therefore crucial. Perfact supports clients in the process industry throughout all phases of a turnaround: from the TAR scan and scope definition, through detailed planning and work preparation, to technical supervision during execution. Our professionals work with tools such as Primavera and Maintasc and follow standardised PMI-PMP methodologies. We combine turnaround expertise with Lean Six Sigma — ensuring that every turnaround not only runs on time but also delivers demonstrable process improvements. References: SABIC, Sitech, INEOS and Covestro.

Q: How does Perfact optimise SAP Plant Maintenance in the chemical industry?

SAP PM (Plant Maintenance) is the nerve centre of asset management in the chemical industry. Many organisations run into difficulties because their SAP data is inaccurate, their maintenance structure is outdated, or staff bypass the system. Perfact combines SAP PM expertise with Lean Six Sigma process thinking to deliver an approach that goes beyond technical implementation: we audit and correct the FLOC/equipment structure and master data, redesign SAP-related work processes, optimise preventive maintenance cycles based on historical data and failure mode analysis, and support staff through the change management process as they adapt to the new way of working. Result: higher availability, lower maintenance costs and an SAP system that functions as a reliable basis for decision-making. Case: PreZero (data migration and SAP process review).

With Chemelot and Brightlands around the corner from our headquarters in Munstergeleen, we know the chemical and petrochemical industry like no other. Perfact supports leading companies such as SABIC, Sitech – Ebert HERA and DSM in process optimization, turnarounds and the secondment of certified Lean Six Sigma specialists. Our consultants and project managers know the plants, the safety procedures and the market. No familiarisation period – immediate deployment in an ATEX environment.

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Why choose Perfact for the chemical and petrochemical industries?

Perfact was founded in the shadow of Chemelot. We understand the complexities of the process industry from the inside out — from ATEX classifications to turnaround scope freezes. Our professionals speak the language of both the plant manager and the boardroom. Clients choose Perfact because we combine Lean Six Sigma expertise with sector-specific secondment services. A single partner for both continuous improvement and urgent capacity issues.

What we do in the Chemicals & Petrochemicals sector

Lean Six Sigma programmes in the workplace — from Yellow Belt to Master Black Belt
Turnaround & Shutdown Management: planning, scope control and execution
SAP Plant Maintenance optimisation — from preventive maintenance to fault management
Secondment of LSS-certified process specialists, TA planners and work planners
Operational Excellence programmes focused on improving OEE and reducing waste
Lean assessments as a starting point for a multi-year improvement programme

Common challenges in this sector

The turnaround is going beyond the scope and is at risk of missing the deadline

Scope creep is the number one cause of cost overruns in turnarounds within the process industry. Without a strict scope freeze and daily progress monitoring, a turnaround can quickly fall a week behind schedule — resulting in plant downtime.

Black Belt or LSS specialist suddenly drops out

A specialist leaving the company or taking sick leave can bring an ongoing improvement project to a standstill for months. In an environment where safety and compliance place constant pressure on operational continuity, this is unacceptable.

SAP PM is not being utilised

SAP Plant Maintenance has been implemented at many chemical companies but is poorly configured. Work orders are not systematically closed, the causes of faults are not recorded, and the preventive maintenance strategy is not tailored to the actual needs of the plant.

OEE improvement is stalling at boardroom level

Lean initiatives often falter after the initial phase because the recommendations fail to take root on the shop floor. They are too theoretical, too far removed from day-to-day practice, or there is too little ownership among the operators and team leaders who are responsible for implementing them.