Transforming Manufacturing Through Digitalization: NOVA Chemicals’ Journey

Transforming Manufacturing Through Digitalization: NOVA Chemicals’ Journey | SPONSORED

At Impact 2024, Ahmed Musa, Digital Manufacturing Lead at NOVA Chemicals, shared insights into the company’s digital transformation, revealing key lessons for manufacturers aiming to modernize their operations. The focus of the discussion highlighted several actionable strategies that can accelerate digitalization, maximize efficiency, and improve reliability—essential takeaways for any manufacturing organization.

1. Addressing Legacy Systems and Data Integration

NOVA Chemicals, a leader in the North American polyethylene market, faced challenges with fragmented legacy systems and scattered data. For manufacturers, integrating disparate systems is a common hurdle that can impede efficiency and innovation. NOVA’s strategy was to partner with Cognite, a leader in the space, to select  a platform that could unify and consolidate their data to provide a single source of truth across their operations.

Investing in a comprehensive platform that connects and integrates various data sources is critical for establishing a unified digital ecosystem. This approach not only streamlines data management but also provides a foundation for implementing advanced solutions like predictive maintenance and automation.

2. Optimizing Reliability and Maintenance

NOVA focuses on reliability as a key value stream, particularly within its older petrochemical facilities. For many manufacturers, maintenance processes are often reactive and time-consuming, leading to inefficiencies and unexpected downtimes. NOVA’s solution involves implementing an end-to-end maintenance strategy that automates routine tasks, such as scheduling and data monitoring while freeing up employees to focus on high-value activities.

By digitizing and integrating maintenance systems, the company has reduced the time needed to access critical information, transforming processes that once took hours into tasks completed in minutes.Modernizing maintenance operations with digital tools can provide significant efficiency gains. A focus on automating repetitive maintenance tasks not only improves reliability but also enables teams to allocate resources toward more strategic activities.

3. People-Centric Digitalization: Ensuring Adoption and Success

NOVA emphasizes the importance of making digital transformation people-centric. Digital tools and systems must align with the needs of those who use them daily—operators, technicians, and plant managers. NOVA achieves this through design thinking workshops that engage these key users in co-creating solutions. This process ensures that technology not only meets operational needs but also has high adoption rates among the workforce.

Involving end users from the start of the digitalization journey is crucial for building solutions that are practical and widely accepted. A people-centric approach reduces resistance, enhances adoption, and ensures that digital tools are genuinely aligned with operational requirements.

4. The Role of Predictive Maintenance

NOVA leverages predictive maintenance algorithms to anticipate equipment failures, schedule interventions, and order parts ahead of time. This proactive approach, increasingly adopted by manufacturers, significantly reduces downtime and stress associated with unplanned repairs. With predictive maintenance, operators gain control over their processes rather than responding reactively to equipment issues.Implementing predictive maintenance boosts operational efficiency and optimizes resource allocation. Manufacturers can benefit by reducing emergency maintenance costs, improving asset reliability, and scheduling maintenance activities when they are least disruptive.

5. Embracing AI and Emerging Technologies

As NOVA continues its digital transformation, the company explores AI to automate routine inspections and operational rounds. However, NOVA emphasizes a gradual approach to building trust in AI systems. Rather than fully automating tasks immediately, the company ensures that human operators remain involved in oversight, building confidence in the technology while maintaining control over critical processes.

Manufacturers looking to mirror Nova’s approach to digitalization should explore how AI can automate high-risk or routine tasks. However, to build trust and ensure effective deployment, a phased approach that integrates human oversight and allows for gradual system adaptation is recommended.

6. Communication and Engagement: The Foundation for Success

One of the most valuable lessons NOVA has learned is the importance of consistent communication. By keeping stakeholders informed and sharing the successes of early adopters, the company creates a culture of transparency and trust. NOVA uses peer-to-peer communication, allowing operators who have experienced the benefits firsthand to share their stories, reinforcing the positive impact of digital transformation.

Frequent and open communication is essential to maintaining momentum during digital transformation. Involving frontline employees and sharing their success stories can enhance credibility, promote widespread adoption, and sustain enthusiasm throughout the process.

Conclusion

NOVA Chemicals’ digital transformation journey provides a roadmap for manufacturers looking to modernize their operations. From addressing legacy systems to implementing predictive maintenance and leveraging AI, NOVA’s strategies showcase the benefits of a well-planned digitalization approach. Manufacturers can learn from NOVA’s experience by prioritizing people-centric processes, investing in robust data platforms like Cognite Data Fusion, and maintaining open communication with stakeholders.

These insights demonstrate that successful digital transformation goes beyond technology—it’s about aligning systems with real-world needs, engaging employees in the process, and building a culture of continuous improvement.

The interview was recorded by Greg Orloff, Industry Executive, IIoT World, and Ahmed Musa, Digital Manufacturing Lead at NOVA Chemicals. Travel expenses for attending the Impact 2024 event were paid for IIoT World by Cognite.