MAVERICK Technologies uses DCSNext solution to move major DCS migration project into final phase

  • August 24, 2016
  • Columbia, Illinois

DCSNext capabilities allow INEOS Styrolution to avoid any additional downtime during migration and leverage the complete benefits of the latest technology

MAVERICK Technologies announces the completion of the second phase of a major DCS migration for its client INEOS Styrolution, a polystyrene manufacturer. MAVERICK applied its DCSNext solution, which takes an innovative approach to DCS migration by considering opportunities for improvement across the entire operation. Thanks to a thorough planning process and team-based dynamic, the entire project was funded upfront; this allowed it to be implemented in concurrent phases during planned outages with no additional downtime.

Leveraging MAVERICK's full capabilities through DCSNext was critical to the project's success. INEOS Styrolution had never before conducted a major DCS migration at its Channahon facility, and its staff was already short on engineering resources. MAVERICK brought in experts from its operations consulting, design, automation services and field services teams to support Styrolution before, during and after the migration.

The upfront funding approval was achieved through a comprehensive front-end loading (FEL) process. Early FEL helped define the overall scope and strategy while outlining the costs, risks and gaps. This allowed Styrolution a clear look at what the full spend would be, and gave the polystyrene manufacturer confidence that MAVERICK could hit all major milestones without exceeding the proposed budget or timeline. Subsequent planning was then performed in parallel with execution to move the project forward without interruption.

In order to eliminate unnecessary downtime, it was essential that all work be completed during the plant's planned maintenance window. An embedded construction manager from MAVERICK's field services group oversaw the entire installation and startup, freeing Styrolution staff to focus on other critical tasks during the outage.

By applying the latest technology and innovations, the team expects to help improve productivity, profitability and agility across the entire operation. Ultimately, this will also include upgrading the existing HMI to a high-performance HMI, which will help improve the efficiency and effectiveness of facility's HMI graphics and screens.

INEOS Styrolution Project Engineer Jason Werner says the company is pleased with the support MAVERICK has provided through its DCSNext solution.

"MAVERICK Technologies is definitely a company that I would recommend to accomplish a DCS project. They worked with us to create unique ideas for implementation of a full system upgrade within a limited outage window," Werner says.

For more information about DCSNext, visit

About DCSNext®

MAVERICK has applied decades of knowledge to create a true breakthrough in DCS migration: DCSNext. More than a simple I/O or equipment replacement, DCSNext helps manufacturers leverage the complete benefits of the latest DCS technology in order to improve productivity, agility and profitability. DCSNext combines a four-step comprehensive study of the DCS migration challenge with a phased approach to execution and ongoing support. This dynamic approach not only brings manufacturers up to speed, but propels them ahead of the competition for years to come. To learn more about DCSNext, please visit

About MAVERICK Technologies®

Founded in 1999, MAVERICK is the largest independent systems integrator in North America, and is a global leader in industrial automation, enterprise integration and strategic manufacturing solutions for clients across a wide range of manufacturing and process industries. Leveraging its unique enterprise-wide perspective, MAVERICK identifies suboptimal operations and improves performance for greater safety, efficiency and overall profitability. The company’s people, processes and technical capabilities ensure delivery of the right solution for every project, using the most appropriate technology. Organizations around the world depend on MAVERICK’s responsiveness, results-driven approach and dedication to their success. Over the years, MAVERICK has completed more than 15,000 projects in 46 countries across six continents. To learn more about MAVERICK, please visit

About ISA

The International Society of Automation ( is a nonprofit professional association that sets the standard for those who apply engineering and technology to improve the management, safety, and cybersecurity of modern automation and control systems used across industry and critical infrastructure. Founded in 1945, ISA develops widely used global standards; certifies industry professionals; provides education and training; publishes books and technical articles; hosts conferences and exhibits; and provides networking and career development programs for its 40,000 members and 400,000 customers around the world.

ISA owns, a leading online publisher of automation-related content, and is the founding sponsor of The Automation Federation (, an association of non-profit organizations serving as "The Voice of Automation." Through a wholly owned subsidiary, ISA bridges the gap between standards and their implementation with the ISA Security Compliance Institute ( and the ISA Wireless Compliance Institute (