Robust Process Control at Cerestar's Refineries

Kumar Rajaram, R. Jaikumar, Franz Behlau, Frans van Esch, Corrie Heynen, Ralph Kaiser, Albert Kuttner and Izaak van de Wege
Additional contact information
Kumar Rajaram: Anderson Graduate School of Management, UCLA, Los Angeles, California 90095, USA
R. Jaikumar: Graduate School of Business, Harvard University, Cambridge, Massachusetts 02138, USA
Franz Behlau: Cerestar Benelux BV, Nijverheidsstraat 1, 4551 LA, Sas Van Gent, The Netherlands
Frans van Esch: Cerestar Benelux BV, Nijverheidsstraat 1, 4551 LA, Sas Van Gent, The Netherlands
Corrie Heynen: Cerestar Benelux BV, Nijverheidsstraat 1, 4551 LA, Sas Van Gent, The Netherlands
Ralph Kaiser: Cerestar Deutschland GmbH, Dusseldorfer Straße 191, D-47809 Krefeld, Germany
Albert Kuttner: Cerestar Deutschland GmbH, Dusseldorfer Straße 191, D-47809 Krefeld, Germany
Izaak van de Wege: Cerestar Deutschland GmbH, Dusseldorfer Straße 191, D-47809 Krefeld, Germany

Interfaces, 1999, vol. 29, issue 1, 30-48

Abstract: With annual sales of over $2 billion, Cerestar is Europe's leading manufacturer of made-to-order wheat- and corn-based starch products. Cerestar relies on refineries that are highly automated and require large fixed investments. Starting in 1993, we developed Robust Process Control (RPC) to increase average throughput and reduce throughput variation by combining engineering principles with OR/MS techniques. RPC includes a mathematical-programming model to reduce downtimes due to product switchovers, models for process optimization, and dynamic control models for process-flow synchronization. Cerestar implemented the resulting decision support system at eight refineries in six countries. It has increased average daily throughputs by 20 percent and reduced average throughput variation by 50 percent. Concomitantly, the refineries have reduced their consumption of supplies and utilities. In addition to over $11 million in annual benefits, RPC has had major strategic and organizational impact.

Keywords: agriculture/food; manufacturing; performance/productivity (search for similar items in EconPapers)
Date: 1999
References: View complete reference list from CitEc
Citations: View citations in EconPapers (7)

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Persistent link: https://EconPapers.repec.org/RePEc:inm:orinte:v:29:y:1999:i:1:p:30-48

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