SLOVAK PRISM SEMINAR 2003 THE ROLE OF COMMUNICATION SKILLS IN ENGINEERING FOR SPECIALTY CHEMICALS INDUSTRIES

1. SLOVAK PRISM SEMINAR 2003THE ROLE OF COMMUNICATION SKILLS IN ENGINEERINGFOR SPECIALTY CHEMICALS INDUSTRIES Paul Krajnik Ciba Specialty Chemicals Ltd Basle, Switzerland Prism Seminar 2003 P. Krajnik Ciba Specialty Chemicals

2. THE ROLE OF COMMUNICATION SKILLS IN ENGINEERING CIBA SPECIALTY CHEMICALS GLOBAL PRESENCE but SOME BEHAVIOURAL DIFFERENCES BETWEEN OUR SITES IN DIFFERENT CONTINENTS Prism Seminar 2003 P. Krajnik Ciba Specialty Chemicals

3. Prism Seminar 2003 P. Krajnik Ciba Specialty Chemicals

4. THE ROLE OF COMMUNICATION SKILLS IN ENGINEERING SPECIFIC TASKS AND DIFFERENCES between • SPECIALTY CHEMICALS INDUSTRY MULTIPRODUCTS but LOW TONNAGE / y MULTIPURPOSE EQUIPMENT MIX BATCH / KONTI MULTISKILLS NEEDS • BULK AND COMMODITIES CHEMICALS INDUSTRY Prism Seminar 2003 P. Krajnik Ciba Specialty Chemicals

5. Process Development Process Design Basic Engineering Detail Engineering Implementation Commissioning Optimization Maintenance Purchase Produktion Marketing End User Research POSITION OF ENGINEERING Technology Raw material Produkt Chemical Industry Prism Seminar 2003 P. Krajnik Ciba Specialty Chemicals

6. THE ROLE OF COMMUNICATION SKILLS IN ENGINEERING AVOID HUMAN ERROR through • BETTER COMMUNICATION • TYPE OF COMMUNICATION • FORMAL EXAMPLES FOR FORMAL COMMUNICATION • HANDBOOK FOR THE PLANNING PROJECTS • R&M HANDBOOK • EHS POLICY, EHS MANAGEMENT • INFORMAL Prism Seminar 2003 P. Krajnik Ciba Specialty Chemicals

7. THE ROLE OF COMMUNICATION SKILLS IN ENGINEERINGERROR TYPE(by T.A. Kletz) Prism Seminar 2003 P. Krajnik Ciba Specialty Chemicals

8. Calendar time of asset (equipment) Programmed Losses Available time Non Programmed Losses Gross Operation Time OPPORTUNITY Yield Losses Net Operation Time $ Value Added Time Defect Losses OEE GAP Overall Equipment Effectiveness Prism Seminar 2003 P. Krajnik Ciba Specialty Chemicals

9. Stilb. EIM ? TQM ISO 9001 SAMACO ? Training Program Culture Assessment GMP EHS Initiative Diverse Programs Prism Seminar 2003 P. Krajnik Ciba Specialty Chemicals

10. GAPS • Education and Training. • Sustainable Systematic Technical Improvement. • Workers Involvement in Technical Improvement. • Identification of Employees with Tech. Op. Goals. Prism Seminar 2003 P. Krajnik Ciba Specialty Chemicals

11. “Total Professional Leadership” Strategic Plan 2002 -> 2005 Capacity CoPA CAPEX Improve Learn People Skills Education Training Culture Norms - Acknowledgement Values - Ownership Behavior - Commitment - Communication TOTAL LEADER SHIP Do Teach Systems / Organization SAMACO TQM ISO 9001 EIM GMP Near Misses Reporting Prism Seminar 2003 P. Krajnik Ciba Specialty Chemicals

12. Education and Training Conservation and actions to avoid recurrance Horizontal replication of acquired knowledge Return to original condition then improvement Prism Seminar 2003 P. Krajnik Ciba Specialty Chemicals

13. Where/How does TPL thrive? • In a stable environment with committed top management • In a cooperative environment between company and workers/unions • As a long–term approach to management of assets • Where support by line management is apparent • Where a good study is done and a sound plan is executed to coordinate actions / initiatives and eliminate gaps • Where it is custom fit to the site needs • Where employees can give input • Where it’s successes are recognized and positively reinforced Prism Seminar 2003 P. Krajnik Ciba Specialty Chemicals