PEOPLE & TEAMWORK Anastasia Bron, Head of Process Management, and process expert Jack Conen at Saltigo’s FFK site (Plant 4). SMAART was rolled out here first. “We are a highly automated plant and SMAART helps us keep track of complex processes. The app immediately shows us if there are any problems,“ says Bron. A SMAART MOVE For over a year now, a new app – SMAART – has been an integral part of everyday working life at most Saltigo plants. It optimizes processes and significantly increases plant capacity. The man behind the idea, Julian Stiller, explains how it works. There are many fascinating things about star chefs, but one thing nev- er ceases to amaze: how do they manage to serve their seemingly individual works of art to so many guests at exactly the same time? “These chefs have definitely optimized the throughput times in their ‘manufacturing processes’ to the absolute maximum,” suspects Julian Stiller, who is responsible for “Continuous Improve- ment” in the Saltigo business unit. It sounds obvious – if every tiny step in the process is perfected, it reduces the time needed to pre- pare the entire dish. Stiller knows what he’s talking about, as he is deeply involved in the task of optimizing throughput times in the chemical process- es at SGO’s plants. This is, of course, part of every production team’s daily routine. But it was Stiller who three years ago thought: we need our own app. It should provide us with a ranking of the systems that have the greatest impact on optimization within a pro- duction process. And it should also make it clear which steps in the process are the most important in that system. This would show us at a glance where we need to take action to optimize throughput time. With an app like 18 Xpress | 04/2024 this, our star chef might see that preparing the stock has the greatest impact on the timing of the entire dish. This is because the stock takes a long time to prepare, and the chef needs it for several further steps. If this process could be optimized, everything else would go faster. Julian Stiller tasked Tobias Siekmann, a stu- dent working part-time at the site, to program the app. Because that was another thing – in these financially difficult times, the project had to be carried out using internal manpow- er. It didn’t take long for Siekmann to code the initial version. Matthias Grabowski, pro- cess manager for chemicals at the FFK plant in Leverkusen, tested it: “Even though the pilot version was still a bit rough around the edges, I immediately recognized its poten- tial,” he recalls. Today, there’s nothing rough about it – the app is finished and was named SMAART, which is a clever acronym for Stan- dardized Method for the Automated Anal- ysis and Reduction of Throughput Times. Now, Grabowski can’t imagine doing his job without the app: “I use it every day to get an overview of the process and initiate improve- ments.” While process experts already had an inkling of some of the optimization poten- tial uncovered by SMAART, numerous oth- er aspects only became apparent through SMAART. “One thing in particular caught my eye thanks to the app,” Stiller says. In a certain process, a substance needs to be cooled down to 70 degrees Celsius so that it can be transferred to another unit. SMAART revealed that this transfer was often delayed, sometimes by up to three hours. Even worse, if the temperature ended up dropping below 65 degrees Celsius, the unit would heat it up again before the transfer – a real waste of energy. SMAART pointed out the relevant INTERESTED? Go to the “What’s Coming Up?” section of Xnet to register for a live demo: 1/14/2025, 10:00 a.m. – 11:30 a.m., Xlearn (German) 1/16/2025, 3:00 p.m. – 4:30 p.m., Xlearn (English) 1/22/2025, 3:00 p.m. – 4:30 p.m., Xlearn (German) The SMAART team: front row from left to right: Michael Reinert, Marcel Dembek, Tatjana Berg, Mattias Grabowski, Rasit Faller. Back row from left to right: Rolf Begemann, Tobias Siekmann, Julian Stiller, Boris Bosch.