01
Completed a 5S event that reorganized the unit warehouse, improved material storage, and reclaimed scrap equipment and materials.
Evonik Industries
Engineering Internship Success Story
Supporting Safety, Compliance, and Continuous Improvement
Evonik's Mobile-area facility is the company's largest North American site. Approximately 700 employees produce hydrogen peroxide, fumed silica, methionine, and other specialty chemicals.
Evonik's MMAT business unit in Theodore, Alabama, requested assistance with 5S projects, a new product launch, packaging complaints, process-safety work, and Department of Transportation requirements.
During the summer of 2016, the Alabama Productivity Center assigned a University of Alabama Chemical and Biological Engineering intern, supported by APC professional staff, to assist with this work.
The Objective
Helping the MMAT Unit Meet Operational and Regulatory Goals
The engagement focused on continuing Evonik's 5S program while also completing projects related to safety, environmental performance, OSHA process-safety management, and DOT compliance.
The intern supported projects across warehouse organization, emergency response, product testing, operating procedures, emissions calculations, packaging, labeling, and engineering documentation.
This broad project scope gave the intern practical experience across both chemical engineering and manufacturing operations.
Project Accomplishments
Improving Processes Across the Business Unit
02
Improved batch-cleanup standards to reduce the risk of contamination in future products.
03
Created a listing and map of emergency notification pushbutton stations to support faster emergency response.
04
Developed laboratory and operating procedures for a new product launch, including PPE requirements and employee training.
05
Improved product-emission calculations submitted to the Environmental Protection Agency.
06
Resolved customer complaints involving product packaging.
07
Completed DOT placarding and labeling compliance checks and updated related procedures.
08
Checked and updated P&IDs, process-flow diagrams, and risk-based inspection documents for process-safety compliance.
Applied Engineering Work
Supporting a New Product Launch
The intern helped Evonik prepare for a new product start-up by writing laboratory procedures to test product characteristics and creating operating procedures for production.
The procedures included guidance for properly handling the new product, selecting required personal protective equipment, and training employees on the updated process.
The intern also improved emissions calculations, updated process documentation, and reviewed P&IDs and process-flow diagrams to support regulatory compliance.
Measurable Results
Project Impact
$2,877,200
Retained Sales
$146,096
Cost Savings
$17,750
New Investments
$3,041,046
Total Impact
Client Testimonial
“
The Alabama Productivity Center intern routinely took initiative and found work by listening in meetings and asking questions. She demonstrated a sound technical background by accurately performing engineering calculations to estimate the time it would take to perform a liquid-liquid azeotropic distillation.
Randy Rogers
Director, Site Communications and Government Affairs
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