European Chemical Manufacturing Masters 2011

Transcription

EUROPEAN
Chemical
Manufacturing
MASTERS 2011
28TH February & 1ST March 2011 | ABION Spreebogen Waterside Hotel, Berlin
17 c a se studies | 4 wo rking group s | live & o n - dem and web co nference
Strategic challenges in chemical production | Operational excellence for increasing productivity |
Intelligent manufacturing systems, automation & BI | Reducing energy consumption
> Operational excellence & process optimisation in the chemical industry: Success indicators and business enablers for plant managers
and global operations responsibilities
> Competitive production through effective and integrated processes in manufacturing, R&D, maintenance & marketing
> Supply chain & production planning: Guidance and focus on the requirement of the business
> Technology & innovation management in (global) chemical manufacturing operations
> Contractor & supplier management in chemical manufacturing operations
> Manufacturing intelligence through coupling BI and process improvement
> Energy management and energy efficiency in chemical manufacturing
> Restructuring operations to achieve operational excellence: Aligning manufacturing, development and quality functions to a common goal
> Implementing operational excellence methodologies in technology transfer
> Systemised control of production & manufacturing intelligence: Integrated IT systems and MES management in chemical operations
> Global & local governance & compliance model for overall quality & process management in chemical manufacturing operations
> Automation infrastructure for operational excellence: Remote operations management, automation services strategy & in-plant
mobility solutions
Profit from speakers such as:
Dr. Stefan-Robert Deibel
Senior Vice President Technology and Production Coordination PU
Basic Products
BASF Polyurethanes / Belgium
Andre de Ruyter
Senior Group Executive, Group General Manager
Sasol Group Services (Pty) Limited / South Africa
Dr. Alexander Struck
Member of the Management, Production Manager
Shell Deutschland Oil GmbH / Germany
Jose Sarmento
Vice President Quality
Borealis AG / Austria
Dr. Jean-François Claver
Vice President Manufacturing Southern Europe
Lafarge Group S.A. / France
David Hodgetts
Managing Director, European Operations Director
Sun Chemical Ltd / UK
Stefan Malmsten
Global IT Leader
Eka Chemicals AB / Sweden
Eward Hofstede
Global Director Manufacturing
DSM Engineering Plastics / The Netherlands
Paolo Bonfanti
Plant General Manager
L‘Oreal S.A. / Italy
Andreas Rizzetti
Industry Solution Architect
SAP AG / Germany
Sponsors
Dr. Ovidiu Marin
European Director, European Energy Management
Air Liquide S.A. / France
Piet Van Loo
Head of Manufacturing BL Caprolactam
Lanxess NV / Belgium
Dr. Carl-Helmut Coulon
Markting & Sales Manager
Bayer Technology Services GmbH / Germany
Dr. Jan Busch
Project Manager Competence Center Process Analysis
Dr. Michael Groschner
Head of Carbid Division
Donau Chemie AG / Austria
Erik Bastiaensen
Site & Plant Manager
DYNEA NV / Belgium
Alex Stok
Site Director
Sun Chemical NV / SA / Belgium
Wolfgang Albert
Head of Automation & Process Management
Evonik Industries AG / Germany
Dr. Cédric Cossy
Head of Plant Support
BASF S.A. / Switzerland
Ben Hopkins
Site Manager
DSM NeoResins / USA
Media partners
EUROPEAN
Chemical Manufacturing
MASTERS 2011
Dear Sir or Madam,
The crisis of 2009 has structured the chemical sector in Europe from scratch.
The resulting increase in inventory levels, costs and savings and the massive
pressure from Asian competitors requires a thorough discussion of methods
and tools to implement a strategic and sustainable production management
in the chemical industry under the impact of global shifts in the market.
Inside the chemical industry, manufacturers are facing immense product
differentiation, fast moving technological requirements, strong environmental and health awareness, and stringent regulations. Therefore
chemical manufacturers must adopt new technology, innovate effectively
and produce in a cost efficient manner and still respect product and
environmental safety.
As chemical companies continue to focus on attaining the next level of
operational excellence, more and more are adopting or expanding their
use of lean or lean Six Sigma across their organisation. As this adoption
matures, companies are looking for ways to standardise their improvement
processes, accelerate their time-to-value in these programmes and find
better ways to measure and monitor the value they are getting for their
investments. Operational excellence can be a highly effective approach
for a maximum of ROI. OPEX is predestined to succeed by using minimum
energy consumption, high product yield and high system availability in
global competition. New OPEX concepts link methodological expertise with
technology innovations securing operational process efficiency. Issues such
as OPEX, lean, OEE, TPM or continuous improvement are just some issues
that will play a significant role in the future of chemical production. These
tools help to rationalise and standardise production processes for cost
savings in terms of manufacturing efficiency, quality and energy and raw
material consumption.
One of the most effective ways to realise this value is by using software,
for example with manufacturing execution systems (MES). Product data
integration and harmonisation facilitates innovation with sustainable
high-tech products, and reconciles short production and product lifecycles
within production efficiency. For the chemical industry, MES functionalities
leverage existing business system investments and infrastructure while
accelerating manufacturing visibility and control. This allows production
and logistics processes to be synchronised so at anytime, products are
quickly and cost efficiently delivered which contributes to maintaining a
competitive edge.
Another effective tool, for example is business intelligence (BI). BI in chemical
manufacturing environments is emerging as a worthwhile investment for
many savvy companies. These firms are starting to realise that the gap
between manufacturing intelligence designed to keep assembly lines
running smoothly and their traditional BI systems is more like a chasm.
If companies with significant chemical manufacturing operations want to
beam light into the dark, they have to make a case for implementing BI that
is capable of creating meaning from manufacturing activity.
Today, the proportion of the chemical industry‘s total sales of the manufacturing sector in Europe is over 10%. In addition to the internationalisation
of the value chain, primarily the requirements of the customers, like price,
availability and quality of the products are the most difficult challenges
chemical companies are facing. The economic crisis had a particularly
strong effect on the chemical industry in Europe, since large areas of the
industry have been affected (especially automotive coatings industry) and
chemical composition of business especially commissioned break-ins.
Now, most chemical companies have reduced their stock excess capacity. It
is now strategically aligned and new production set-ups are ready for a new
and changed market. The European chemical industry has to focus on new
challenges in a rapidly changing market. The “European Chemical
Manufacturing Masters 2011“ will discuss challenges and solutions for
chemical manufacturers across all over Europe!
We look forward to welcoming you in Berlin!
Your econique team
Tanja Niemann
Senior Manager International Projects
Phone: +49 (0)30 802080 458
Fax:
+49 (0)30 802080 430
Email: [email protected]
www.business-masters.econique.com
Who participates on the European Chemical
Manufacturing Masters 2011?
The European Chemical Manufacturing Masters 2011 is attended by
decision-makers and opinion leaders from the following departments:
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Production / Manufacturing
Production planning / controlling
Process excellence
Plant management
Six Sigma / OPEX / Lean
Risk / EHS / Energy
Operations
IT
Supply chain
Technical operations
(Technical) Engineering
from all chemical companies across Europe
Format
> Best practice presentations: More than 15 carefully selected business
cases
> Working groups: Pre-matched informal working groups with experts
> Networking zone: Optional one-to-one-meetings based on interests
and experiences
> experts circle: Virtual collaboration and networking room on the web
Recent feedback on the econique business masters series
“econique brought together top representatives from all
over Europe to share real-life strategies, experiences &
best practices. It was a rare opportunity to learn from
impressive and proven advice, in addition to networking
with peer experts from throughout the world.”
Michael Elliot
Instrument Plant Lean Leader / Operations
BD Diagnostics
“I personally found it to be an outstanding conference,
both for scientifically content of presentations and
discussions and also for the networking opportunities.”
Ferruccio Migliorini
Director / Eng / Maint / HSE Senior Manager
Eli Lilly Italia S.p.A.
“The most professional maintenance event in Europe.“
Fabrice Brion
Directeur
I-Care
(Sponsor at the European Pharma Maintenance Masters 2010)
EUROPEAN
MASTERS 2011
Tanja Niemann
Phone: +49 (0)30 802080 458
Fax:
+49 (0)30 802080 430
Agenda | M o nday, 28 th February 2011
8.00
Registration
8.30
Welcome and introduction through econique and from the Chair
Operational excellence & process optimisation in the chemical industry: Success indicators
and business enablers for plant managers and global operations responsibilities
8.45 I Case Study
An effective and integrated technology function with a business unit
enables a competitive production and optimized link between marketing,
R&D, production / manufacturing and maintenance
>Continuous process improvement via internal and external benchmarking
needs to be institutionalised
>Maintenance needs to understand the marketing needs and marketing needs to
understand what their requirements mean to maintenance / production
>R&D needs to be tracked in a stage gate process and needs to be derived out of a
Marketing strategy and Technology needs/opportunities (market push and pull)
>Balanced Score cards need to be implemented to “balance” the activities and needs
Dr. Stefan-Robert Deibel, Senior Vice President Technology and Production
Coordination PU Basic Products, BASF Polyurethanes / Belgium
9.30 I Case Study
Benefits of automation: How can automation improve the efficiency
of production plants?
>With state-of-the-art automation procedures it is possible to reach a
significantly higher efficiency level in chemical production plants.
These objectives can be achieved in a short period of time and by means of
moderate funding. The cost / benefit ratio is usually excellent
>Examples of real and already proven implementations like process knowledge,
simplification & robustness
>The two automation areas concerned in this context are process control & process
management
>In the control environment the benefits of applying model-based control as a
replacement of PID control are emphasised
>In the management area the importance of process information management (PIM)
is outlined. With PIM and especially the applications and evaluations based on this
information, improvement potential can be identified which again form the
starting point for well-directed optimisation efforts
Wolfgang Albert, Head of Automation & Process Management,
Evonik Industries AG / Germany
10.15 I Networking Zone
Refreshment break
Individually organised one-to-one meetings you can determine in the online community
during the econique experts circle agenda personalisation phase prior to the conference.
10.45 I Case Study
Key account customers as the trigger for process change in chemical
manufacturing
>Challenge of oligopolistic customer structures: Differentiation as key for
success
>How to find one’s own strength: Company strategy and customer needs
>Implementation, tools & process management
>Integration of strategy in manufacturing excellence
>Implementing a successful production planning system to manage and reduce
time-to-market / time-to-customer
Dr. Michael Groschner, Head of Carbide Division, Donau Chemie AG / Austria
11.30 I Case Study
Global governance & compliance model for overall quality & process
management in chemical manufacturing operations @ Borealis Group
>The Governance Model
> Integrating Values, Principles, Strategy and Policies in a coherent business frame
>Fighting bureaucracy get simplicity
> Develop a “Lean Management System” to achieve higher levels of compliance and control
>People impact: a matter of “engagement”
>Challenges and success factors in manufacturing areas / at plant level
>First results and outcomes of the program
Jose Sarmento, Vice President VP Quality, Borealis AG / Austria
12.15 I Case Study
Change management & OPEX @ L’Oreal Italy
Paolo Bonfanti, Plant General Manager, L‘Oreal S.A. / Italy
Lunch
Energy management and energy efficiency in chemical manufacturing
14.00 I Case Study
Energy management and Energy efficiency in chemical manufacturing
Piet Van Loo, Head of Manufacturing BL Caprolactam, Lanxess NV /
Belgium
14.45 I Case Study
Implementing an integrated approach for energy and carbon
management for optimising costs in manufacturing operations
>Integrated approach for energy and carbon management
>Keeping control of emissions and thus lowering CO2
>How to raise awareness on carbon issues with the different stakeholders within
the company
>Greenhouse gas emissions along the value chain: Producers, customers and
suppliers
Dr. Ovidiu Marin, Director, European Energy Management, Air Liquide S.A. / France
Refreshment break
Restructuring manufacturing operations after the crisis in the chemical industry
16.00 I Case Study
Restructuring operations to achieve operational excellence:
Aligning manufacturing, development and quality functions to a
common goal
>Developing a flat and cross-functional process-oriented organisation
in manufacturing
>Achieving significant reduction in throughput time, and enhancing “right first time“
processes
>Defining clearer responsibilities during technology transfer to improve efficiency
>Improving transfer of know-how from development to manufacturing
Dr. Jean-François Claver, VP Manufacturing Southern Europe, Lafarge Group S.A. /
France
16.45 I Case Study
Sasol Olefins & Surfactants: A turnaround to sustainable profitability
>Redefining the O&S business model
>Portfolio optimization – a model for sustainable profitability
>Information management’s role in supporting the turnaround
>Culture changes required to effect sustainable improvement
Andre de Ruyter, Senior Group Executive, Group General Manager,
Sasol Group Services (Pty) Limited / South Africa
17.30 I Case Study
Increasing productivity and restructuring manufacturing by
implementing an overall change management programme at
plant level
>Implementing change management in the manufacturing
environment
>Implementation of KPI´s and measuring workforce
>Targeting plant leaders and integrating them into the change management process
>Behavioural management & human error prevention for increasing quality and
safety in DSM manufacturing operations
Eward Hofstede, Global Director Manufacturing, DSM Engineering Plastics /
The Netherlands
18.15 I Panel discussion
Strategic management of complexity in chemical production with
selected speakers of the day
Evening reception
EUROPEAN
MASTERS 2011
Tanja Niemann
Phone: +49 (0)30 802080 458
Fax:
+49 (0)30 802080 430
Agenda | Tuesday, 1 st M arch 2011
8.00
Registration
Lunch
8.30
Welcome and introduction through econique and from the Chair
Systemised control of production & manufacturing intelligence:
Integrated IT systems and MES management in chemical operations
8.45 I Case Study
Increasing efficiency in continuous & batch manufacturing through
intelligent & integrated MES systems
>How to achieve a lean production site through automation
>Integration of DCS system and Oracle ERP
>Automation of batch processes
Erik Bastiaensen, Plant Manager, DYNEA NV / Belgium
9.30 I Case Study
Manufacturing Execution through Servant Leadership
>Servant leadership implementation to provide a positive impact to the
three core processes (the people process, the strategy process, and the
operations process), ultimately resulting in manufacturing execution
excellence
>Developing a culture of Servant Leadership at all levels in an organization requires
the correct view of management versus leadership and if properly implemented
and maintained produces a positive change to the overall manufacturing operation
>People are your greatest asset, so bet on people not on strategies
>Hire, develop and retain top talent for mfg. success
>Focus on the 7 essential behaviors for Manufacturing Execution (‘Being versus Doing’)
Ben Hopkins, Site Manager, DSM NeoResins / USA
European chemical manufacturing best practice forum
10.15
Introductory short presentations (15 mins) for the working groups
Topics are free to choose
>> Working Group 1
Process excellence and
business improvement
in safety/regulatory,
production, logistics,
purchase, quality control/quality
assurance and maintenance
Alex Stok, Site Director,
Sun Chemical NV / SA / Belgium
>> Working Group 3
Realising the digital factory of the future:
From vision to reality
>Standardising and harmonising
manufacturing IT
>Integrating the product and production
lifecycles for high flexibility and faster
time to market
>Efficient engineering through simulation
and virtualisation
>Sustainable manufacturing and supply
chain management
tbc
>> Working Group 2
From quick checks and
energy efficiency to a
systematic and fully
integrated energy management system
for maximum ROI & business value in
chemical manufacturing
> Energy quick checks
> Full scale climate checks
> Efficiency management solutions
Dr. Carl-Helmut Coulon, Markting & Sales
Manager, Bayer Technology Services
GmbH / Germany
Dr. Jan Busch, Project Manager
Competence Center Process Analysis,
>> Working Group 4
SAP Deutschland AG &
Co. KG / Germany
>Production and capacity
management
>KPI monitoring
>Simulataneous visualisation of business
and shopfloor data
>Real-time OEE
>The human factor: Personnel integration
of visual factory
Andreas Rizzetti, Industry Solution
Architect, SAP AG / Germany
11.15 I You have the choice between:
>Pre-organised working group on one of the presented topics
- or >Individually organised working groups which you can determine in the online
community during the agenda personalisation phase prior to the conference
12.15
Panel discussion on the top topics of the European Chemical Manufacturing Masters
with reports from the working groups and the econique “experts circle”.
13.45 I Case Study
Horizontal process integration in the chemical industry and their
mapping in an innovative MES architecture in 40 plants worldwide
>Initialisation by grown heterogeneous IT landscape
>Gearing of core processes: Potential for an integrated solution
>Migration strategies
Stefan Malmsten, Global IT Leader, Eka Chemicals / Sweden
14.30 I Case Study
Manufacturing intelligence through coupling BI and process
improvement
>Architecture for the coupling of MES and business intelligence for
optimising process excellence in manufacturing operations
>Manufacturing integration & intelligence
>Fast reports & BI tools in manufacturing
David Hodgetts, Managing Director, European Operations Director, Sun Chemical Ltd / UK
HSE, risk & quality management in chemical operations
15.15 I Case Study
HSE from an Executive’s point of view: Turning complaints into efficiencies
>Upside of the downturn: HSE management strategies to prevail in the recession
& thrive in the aftermath
>Process safety indicators for successful HSE management: Small steps-big wins
>Risk management for sustainable safety performance: When low is good enough?
tbc
Refreshment break
16.30 I Case Study
Ensure safe production program from Shell: Challenges, experiences
and results
Dr. Alexander Struck, Member of the management,
Production Manager, Shell Deutschland Oil GmbH / Germany
Contractor & supplier management in chemical manufacturing operations
17.15 I Case Study
Competitiveness: “You’re only as good as your infrastructure
supplier is” – Production of chemical specialties: Multi-company
production site
>User’s owned joint venture for infrastructure supply
>Energy supply, production and distribution
>Treatment of chemical wastes
>Facility management
Cédric Cossy, Head of Plant Support, BASF S.A. / Switzerland
18.00
Closing words from the Chair / End of the conference
We would like to thank everyone who has helped with the research and
realisation of the „European Chemical Manufacturing Masters 2011“,
in particular the speakers for their continued support and commitment.
Henry Fuchs, Director Conference Production,
econique business masters GmbH & Co. KG
EUROPEAN
MASTERS 2011
Tanja Niemann
Phone: +49 (0)30 802080 458
Fax:
+49 (0)30 802080 430
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EUROPEAN
MASTERS 2011
Tanja Niemann
Phone: +49 (0)30 802080 458
Fax:
+49 (0)30 802080 430
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European Chemical Manufacturing Masters 2011

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