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With innovative Technologies towards Operational Excellence

With innovative Technologies towards Operational Excellence. Dr. Helmut Mothes Process Technology 2008-9-30. Turnover worldwide 400 Mill. € Employees worldwide 2800 Client industries Health Care Crop Science Material Science/Polymers Chemicals.

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With innovative Technologies towards Operational Excellence

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  1. With innovative Technologies towards Operational Excellence Dr. Helmut Mothes Process Technology 2008-9-30

  2. Turnover worldwide 400 Mill. € • Employees worldwide 2800 • Client industries • Health Care • Crop Science • Material Science/Polymers • Chemicals Offers services onexternal market BayOpX – Bayer Technology Services in Bayer Holding Company Group Management Board Corporate Center Bayer AG Business Areas Service Areas Bayer HealthCare Bayer CropScience Bayer MaterialScience Bayer BusinessServices Bayer Technology Services CURRENTA

  3. BayOpX – Bayer Technology Services Product & Process Innovation Engineering Procurement Construction Process Optimization Troubleshooting

  4. BayOpX – Operational Excellence: Hype or Opportunity? Quelle: Process 12/2007

  5. Regulatory Affairs Global Competition Technological Progress BayOpX – Operational Excellence: Hype or Opportunity? Operational Excellence with BayOpX – Operating your Site, Plant or Process most efficiently! Operational Excellence ?

  6. BayOpX – Operational Excellence @ BTS Operational Excellence as an Optimization Problem: • Minimize (Operational Cost) = f (Raw Materials, Energy, Personnel, Capital) Meeting the constraints: • Achieve demands in product quality and volumes, • Use existing facilities and infrastructure, • Foresee trends for raw materials and energy supply, • Be flexible for any new requirements (markets, prices etc.) Operational Excellence means superior performance executing daily business processes

  7. Assessment Solutions Implementation Raw Materials & Energy Savings Energy Materials Assets Technology Capacity Management Asset Management Technology Management Operational Excellence requires an integrated Approach BayOpX – From Technology to Operational Excellence Products & Processes Performance @ Customer Technology & Method Know-how @ BTS

  8. Raw Material Utilization (Yield) • Energy Consumption • Plant & Equipment Reliability • Working Capital • Human Resources ASSESSMENT Targets • Availability Analysis • Capacity Map • Pinch Point Analysis • Heat-Power Integration • Risk based Inspection • Supply Chain Concept D C M SOLUTION I A Methodologies IMPLEMENTATION • Pinch Point Software • Prince/KBI Software • Condition Monitoring • Training Simulation • Process Analyzers Tools for a sustainable Implementation BayOpX – Operational Excellence @ BTS - Approach BayOpX – Approach provides Targets, Methodology and Sustainability

  9. Identify customer’s needs as independent consultant • Identify relevant KPIs from first principles and control objectives • Develop benchmarks from best-practise or theoretical optimum • Estimate economic benefit • Milestone 1: Targets Set & Strategy Defined • Analyze system in detail • Identify performance impacting parameters • Design and customize methods and tools • Milestone 2: Solutions Designed & Evaluated • Implement monitoring and control functions • Train plant personnel • Integrate into workflow • Monitor and sustain improvement • Milestone 3: Solutions Sustainable Implemented Define Measure D C M Analyse I A Improve Control Operational Excellence requires Methodology BayOpX – A general Methodology for Solutions

  10. Equipment & Utility Guidelines Energy & Utility Systems Process Improvements Process Control & Automation Define Equipment Check Operational Improvements Measure D Heat Integration & Heat Recovery C M Facility Check / Buildings Analyze I A Pinch Technology Process Modeling min heating demand Improve pinch point Control TEMPERATURE heat integration possible min cooling demand ENTHALPY BayOpX provides powerful Methodologies BayOpX – Energy Audit / Climate Check Methodology

  11. C1 A profitable Define 3 years ROI B Profitability Measure D not profitable C M Bubble Size = Savings Potential Analyse C3 C2 I A easy difficult Improve Technical Feasibility Control A = feasible and profitable B = likely feasible and profitable, needs further evaluation C1=technically (currently) not feasible, but profitable, C2=technically feasible, but not profitable C3 = technically (currently) not feasible & not profitable Steam Electricity Coolants Gases BayOpX – Improvement Project Portfolio BayOpX promotes profitable Projects

  12. Define Measure D C M Analyse I A Improve Control BayOpX – Sustainable Implementation BayOpX takes care of Sustainability

  13. Define Measure D C M Analyse I A Improve Control BayOpX – Improvement Project Portfolio BayOpX provides powerful Monitoring Solutions

  14. Production losses Train (not to scale) PLM+MDT: Market caused Part Load or Downtime PLE+EDT: External caused Part Load or Downtime PLS+SDT: Scheduled Part Load or Downtime Define PLI+IDT: Internal caused Part Load or Downtime loss hours per year [h/a] PST: Planned Part Load or Shutdown Time Measure D 1: Model the plant interactions Unit I Unit II Unit III Unit IV Unit V Unit VI 2: Assign downtimes to individual units C M Analyse I A 18% 16% 14% Improve 12% 10% Propability 8% 6% Control 4% 2% 0% Production (kt/a) 3: Simulate potential downtimes 4: Predict statistical on-line availability BayOpX facilitates Strategy Development BayOpX – Availabiliy Analysis / Capacity Map

  15. Define Capacity (normalized) Measure D C M Analyze I A Capacity Increase / % Individual Equipment or Unit Improve Control Scenarios BayOpX supports Decision Making BayOpX – Scenarios for beneficial Strategies

  16. Identify gaps & opportunities Inspection/ Maintenance Score Card • Covered equipment • Strategy rules/best practices/software • Determine costs Analysis RBI Assessment concept • MI program & procedures • Inspection procedures • Training of engineers & operators • Subcontractors • Inspection technologies Idea Generation D C M RBI Implemen-tation concept Assessment I A Implementation Day2day business support concept • Inspection management software • SAP PM integration • Defect elimination/Asset policies • Continuous improvement Sustainability Control mechanism • KPI’s • Benchmark of comparable units BayOpX enables Asset Management Solutions BayOpX – Risk Based Asset Management Methodology

  17. Create and Update Criticality Calculations Collect and Update Equipment Data Inspection History Analysis Criticality Create and Update Inspection Plans Equipment & Process Data Idea Generation D C M Inspection Planning Assessment I A Implementation Initiate and Resolve Non Conformances Inspections and Tests Sustainability Perform and Document Inspections and Tests Non Conformances BayOpX supports sustainable Performance with Software BayOpX – Performance Monitoring for Asset Management

  18. From Lab ... Capital Investment ... to Manufacturing Lab Technology Unit Transfer Implementation (PCS) Implementation(Hardware) Plant Modification Packaged Units BayOpX – From short-term to sustainable Performance Operational Excellence requires Visions

  19. BayOpX – Project Experience and Results BTS Project Results: Start of project: 100%End of project: percentage below BayOpX delivers Results for Operational Excellence

  20. info@bayertechnology.comwww.bayertechnology.com

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