SyMax Solvay/Syensqo Maintenance Excellence Transformation

Client: Solvay & Syensqo USA, Global Manufacturing Leader

Led by: Lee Bellis, GEMBEX Founding Consultant

Lee, Lead a team of Lean Engineers with PSW Integrity to help coach Solvay & Syensqo in USA to implement SyMax which means Syensqo Maintenance excellence

The ambition is to build a best-in-class reliability framework powered by digital work order processes. The focus is on reducing unplanned downtime, optimizing resources, and improving OEE through preventive and predictive maintenance. By implementing robust scheduling, autonomous maintenance, and spare parts optimization, we aim to deliver sustainable performance across the asset lifecycle.

Gold text that reads 'Objectives' with a black background and three sparkles or stars.

  • Implement a standardized Work Order Management (WOM) program across Solvay / Syensqo Composites Materials sites (Havre de Grace, Kalamazoo, Anaheim, Orange) for consistent execution and tracking of maintenance activities.

  • Establish a clear Maintenance and Reliability strategy aligned with corporate objectives, enabling structured workflows and accountability.

  • Develop an OEE improvement roadmap supported by accurate data capture and analysis, including identification of capital investment needs.

  • Enhance asset reliability, reduce downtime, and align maintenance activities with strategic business goals to support operational continuity and deliver fixed cost savings.

Gold glittery stars behind the text 'Actions Taken' on a black background.

  • SyMax Coaching: Conducted deep-dive diagnostic and SyMaX (Syensqo Maintenance Excellence) transformation at Four sites.

  • Compliance & Governance: Ensured full adherence to EH&S, HR, Trading Standards, and internal business controls

  • Process Standardisation: Developed and implemented SOPs, systems, and procedures aligned with best-practice standards

  • Capability Building: Coach on Bad Actors and get to the root cause of bad actors meaning machines with the most issues and from this we do KT Training (Root cause Analysis) and coach and continually improve the skills of the engineers and production on this methodology.

The image contains the word 'Results' in gold font with three sparkling star-like graphics on a dark background.

  • Standardised WOM processes successfully delivered across three sites.

  • Improved data-driven maintenance practices and resource allocation.

  • Enhanced safety compliance by reducing unplanned interventions and ensuring adherence to maintenance protocols.

  • Enabled predictive maintenance strategies through integration with condition monitoring.

  • Cultural shift toward structured, digitalized maintenance supported by site management and Global Business Unit.

Black background with gold sparkles and the text 'Lessons & Legacy' in gold font.

This project showed that collaboration and rapid implementation are key to success. Accurate data capture was vital for improving reliability and OEE. Across three sites, we delivered 209 SAP profiles, 99 Neptune profiles, and 58 tablets, enabling digital workflows and real-time data access. The legacy is a standardized, digitalized maintenance framework that strengthens safety, sustainability, and cost efficiency while fostering a culture of data-driven decision-making.