Accurate accounting of feedstock inputs, product outputs and manufacturing losses is critical to maximizing operational and financial performance. A plant-wide production accounting system is the first step towards any loss control initiative. We offer state-of-the-art technology that enables production accounting and data reconciliation. In addition, we can provide loss studies which incorporate benchmarking performance against best practice, and development of product loss management programs.
Related case study
Production accounting: Mass balance and data reconciliation
ANCAP, the national oil company of Uruguay, approached KBC as they were looking to replace their obsolete production accounting systems. The new system would need to cover ANCAP’s hydrocarbon business consisting of a crude oil reception terminal with a total capacity of 536,000 m3, an oil refinery with a capacity of 50,000 b/d and 6 distribution plants for refined oil products located strategically throughout the country.Read case study
We offer deep industry and operations domain knowledge to ensure you focus on the right KPIs and set realistic operating targets. Many of our software applications include robust built-in data reconciliation algorithms to eliminate interpretation errors due to bad or missing data.
Feedstock is the biggest operating cost for most plants. We offer deep know-how of industry and production economics, coupled with high fidelity simulation models to allow accurate prediction and optimization of feedstock choices.
We offer high fidelity simulation models of process facilities to faithfully represent reality, utilizing fundamental chemical and mechanical principles to create accurate digital twins of process facilities. Our subject matter experts can then provide advice and opinion to enhance yield performance and throughput.
We offer industry-leading energy and utility system optimization technologies and consulting advice enabled to identify a multitude of cost, environmental and operating improvements that balance the yield-energy trade-off.
Distribution and supply chain optimization
Our process simulation software enables optimal feedstock selection and identification of potential imbalances between interdependent operations. Our cloud services monitor product inventories and process operations and extend the visibility of your supply chain beyond the plant.
Asset integrity assurance
Manufacturing facilities only generate value when they are running. We offer consulting solutions focused on asset strategy, leadership alignment and governance model development, through to reliability assurance, online maintenance and shutdown maintenance support.
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