Operational Excellence & Innovation

ICL’s Operational Innovation unit implements breakthrough methods in the corporate’s operational performance, through cutting-edge technologies and innovative culture methodologies. \

One of ICL’s most strategic activities is the ICL Lighthouse Program, aimed at converting ICL plants into smart factories. To do this, ICL has developed a unique strategy which invests in employee skill development for jobs of the future. This includes providing citizen data scientist certification, training business intelligence developers, augmented reality developers, drone operators, as well as creating expertise in 3D scanning and printing and more. The methodology is based on years of experience and hundreds of Industry 4.0 projects, which created significant improvements in production performance, higher efficiency in raw material utilization, lower energy consumption, increased production capacity and yield, decreased by-products waste and improved sustainability.

The methodology consists of five pillars:

Artificial Intelligence implementation for autonomous process control
Using robotics and drones for inspection, operational and maintenance activities
Improving the flow of information using virtual and augmented reality
Using IoT and smart sensors to continuously measure the quality of process materials and finished products
Implementing IoT for predictive maintenance

Drones and autonomous robotics used at ICL sites are equipped with smart sensors that perform inspection routines from above, prevent employees from working in hazardous areas, decrease site traffic and enable quick and accurate execution of operational routines.

This is in line with ICL’s strategy of top-tier safety performance and environmental responsibility. With regards to safety, ICL has fostered a strong safety culture and enhanced awareness, achieving top quartile safety performance scores within our respective industries. As for environmental responsibility, the Company operates with a clear commitment to full environmental compliance and beyond, which also proactively ensures ICL’s Right to Operate. Various tools and systems are used to reduce environmental impact. These tools include systems to reduce air emissions such as dust that have been implemented and thermal analysis which is used to track and reduce energy losses.

Using Drones for Operational Routines

Drones have become an effective tool in completing tasks that could otherwise be dangerous if undertaken by humans. In an industrial plant setting in addition to saving time and money, it provides a big-picture perspective of line efficiency. ICL’s sites in Israel, in collaboration with ICL’s Operational Innovation Unit, have implemented autonomous drone systems to provide a full range of services at ICL’s Dead Sea, Rotem, and other sites, including: inspecting high voltage networks, monitoring equipment, maintenance inspections in hard to reach and/or dangerous areas, monitoring security systems, improving safety, delivering samples to labs and operating autonomous robots to perform routine field inspections.

Wearable and Accessible Technology

ICL’s vision is to use wearable technology combined with VR to help field operators connect to control rooms, provide remote support, use VR and simulators for safety training activities, and enable hand-free technology. Implementation will partly focus on virtual safety training, event simulations, and training of employees for appropriate responses. Wearable technology, combined with virtual reality (VR) capabilities, has created an opportunity to access, and improve the flow of information in operational, maintenance and safety routines.

As part of the Lighthouse transformation strategy, ICL has begun developing smart workstations that enable the delivery of visual 3D instruction for maintenance teams. This technology enables sharing best practices and improving maintenance quality.

Machine Learning and IoT

ICL implements big data based machine learning models to optimize production line performance and identify potential failures. The outcome is safer, more efficient, and allows more robust process control.

ICL’s IoT solutions for predictive maintenance include an ultrasonic imager that identifies air pressure leaks and electricity disturbances, as well as smart vibration sensors that predict equipment failures and suggest appropriate repair.

Finding new applications for waste streams and products through data mining and AI

Several of ICL’s product and by-product streams can be used as raw materials for additional products or applications, thus promoting reuse and supporting a circular economy.

ICL uses data mining to expedite the discovery of potential applications and has already enjoyed breakthrough results for new uses of its by-products. The strategy is to use data mining to analyze a huge number of articles and patents to identify similar raw materials that have the same properties as the by-product and identify additional uses for them.

Creative thinking methodologies

ICL is implementing Systematic Inventive Thinking (SIT) methodologies, which promote cross learning, creativity, in depth analysis and methodological investigation. By combining SIT’s creative thinking techniques with employee’s knowledge, knowhow, and experience, ICL leverages its resources to increase efficiency, enhance problem solving capabilities, and create more impactful solutions.