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GE Advanced Materials Outsourcing Process and Document handling of the Bergen op Zoom Plant Engineering Department Jan Hellings. A global and diversified technology, media, and financial services company. Healthcare. Transportation. Energy. Commercial Finance. Infrastructure.
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GE Advanced Materials • Outsourcing Process and Document handling of the Bergen op Zoom • Plant Engineering Department • Jan Hellings
A global and diversified technology, media, and financial services company. Healthcare Transportation Energy Commercial Finance Infrastructure NBC Universal Consumer Finance Insurance Solutions Equipment Services Consumer & Industrial Advanced Materials
Advanced Materials Commercial Finance Consumer and Industrial Consumer Finance Equipment Services Energy Healthcare Infrastructure Insurance NBC-Universal Transportation Total GE Consolidated Revenue A company with a strong track record of performance for all stakeholders Automotive Plastics Polymershapes Quartz Sealants & Adhesives Silicones Specialty Film & Sheet 2003 Revenues (USD$ billions) 7.0 20.8 12.8 12.8 4.4 19.0 10.1 3.0 26.2 6.8 13.5 134.1
A company whose actions and values go hand-in-hand Actions Values
Our Company has Global Reach 15,000 Employees in 79 Locations in 21 Countries 4 4 2 1 4 1 2 31 1 2 2 6 4 2 3 2 2 1 3 1 1 79 Locations worldwide, includes manufacturing, technology and joint-venture sites
GE Advanced Materials BOZ • 6 Compounding Plants • Noryl • Lexan • FCP • Lexan-sheet • Slilicones • Azdel • 6 Chemical Plants • 2 BPA Plants • PC Resin • Phosgene Plant • Chlorine Plant • PPO Plant
The need TOP down directive • Problem definition • We had to hit our indirect spend and headcount targets in a fast and effective way. • We created a leaner organization meaning 67 % reduction of our GE-AM engineering headcount (9 to 3 FTE’s) and all engineering freelancers (ca.40FTE’s) • This had a direct impact on how we can execute projects. GE-AM personnel focus on core activities Cost Variable with demand Optimal use of external expertise Respecting company regulation and legislation Change Systems and Structures to Maintain Performance
Finishedgood Raw mat. Production Technical Support Organization • Content of Agreement with • Engineering Service Provider • Project management & risk control full cycle • in Time, Cost and Quality • Engineering services • Procurement • Specs and Standards • Document Control • Consultancy • Environmental, health, Safety & Risk • Maintenance • Strategy • Safe reliable Operation • Cost variable with demand • Optimize usage of external expertise • GE-AM-Focus on core activities • One team One approach, Synergy • Compliance to Asset (psm) • integrity & legislation
The Model Described in an outline strategy • Selection criteria: • Flexibility / Ability to adopt GE culture . • Understand the Vision/Strategy • Price • Size of Organization • Global Player • Local Presence • EHS Performance • Management Commitment • Level of knowledge GE facility • Both Services & Project management • Proven capability, benchmarked Engineering Service Contract Project Identification Scope Definition Operation Close-Out Project Deliverables DFSS Checkpoints T 3 T 4 T 5 T6 Project Identification Scope Definition Conceptual Design Basic Engineering EPC Comm Operation Close-Out T1 T2 T3 T4 T5 T6 GE-AM DFSS process owned by GE- project owner GE-AM selected
T1 T2 T3 T4 T5 T6 Man.of Change - process Project exec. process Investment process DFSS approach as a Tool • Big Y’s External CTQ’s • Growth • Customer satisfaction • EHS • Employee satisfaction • Cost Virtual defect free Improvement Meeting all CTQ’s Project Identification Scope Definition Conceptual Design Basic Engineering EPC Comm. Operation Close-Out GE Aker Kvaerner GE Project Specification & Work Order CDP & GEP Purchase order BEP & Release for Construction Commis- sioning Pinkcard Close-Out Blue card GATS/WtW Sourcing E-MOC GAP 20 DFSS 1 Process for all Projects
GE-AM defines the problem (Y y) and AK takes care of the x’s GE-AM controls the project budget in GE-AM systems System Contract AK runs the schedule and takes care of the engineering workflow AK delivers specialists, sound engineering and project management AK delivers “engineering robustness” T 3 T 4 T 5 T6 GE-AM controls the project/EHS risks through the DFSS process for small or large projects GE-AM sets Role’s & Responsibilities via DFSS process GE-AM assures the Management of Change process DFSS approach as a Tool EPC CDP BEP GEPE drives, Service Provider Powers
É É WtW Report Progress Report Budget Hrs used approve approve Close out É Hrs Sourcing Maintenance Project management É GE-AM systems GE-AM project owner Wing to Wing (=Investment system) Aker Kvaerner – project owner Aker Kvaerner acting as if they are GE-AM
GE-AM server in BoZ (200.000 documents As-built and read-only) AKES server in Antwerp (200.000 documents As-built and projects) • Document viewer Dv TDM • Curator (future) • Eng. Website • (PDF files) As-Built documents (AutoCad, Microstation, PDF etc.) Via VPN connection via ADSL Document Control eB and Documentum Server Server Microstation data 3rd parties: Project & Revision control GE-AM users • House contr. • Vendors Smartplant Explorer Webserver for P&ID’s PDS Oracle Database GE-AM Document Requests AKES team • Project 1 • Project 2 • Project 3 • Etc. Printer Oracle data As-built info As-Built P&ID’s Microstation files and as PDF file PDS 2D for P&ID’s As-Built P&ID’s via PDS Oracle dump Via mobile HD Document Management between GE-AM and Aker Kvaerner
The next step What is system contracting System Contractor Basic Engineering Conceptual engineering GE Basic Engineering Engineering Procurement Construction GE Conceptual engineering Engineering Procurement Construction GE Construction E/I GE System Contractor Construction M&P GE Construction M&P Construction E/I Construction P/A Construction Support Construction P/A Construction Support GE
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