4-Team optimization of multi-reaction batch process

Problem: Models of batch process showed way to increase throughput by 300%
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Group Think: A process run for 31 years was already optimized, little left to improve
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Enabling idea (by DB): Split batch and keep reactor full
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Problem with idea: at one point in optimized concept liquid would solidify and fail to work
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2nd enabling idea (by TB): Cut back slightly on productivity goals until process would work reliably
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Result: Increased throughput 200%, saved $21MM in capital
Increase forecasted NPV from $23MM to $77MM and project got approved
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Creative advantage: Normal project management would kill low ROI project and miss profits.