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

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Presentation on theme: "With innovative Technologies towards Operational Excellence Dr. Helmut Mothes Process Technology 2008-9-30."— Presentation transcript:

1 With innovative Technologies towards Operational Excellence Dr. Helmut Mothes Process Technology

2 Indista – Dr. H. Mothes Page 2 Corporate Center Bayer AG Service AreasBusiness Areas Group Management Board Holding Company Bayer Business Services Bayer Technology Services CURRENTA BayerHealthCareBayerCropScienceBayerMaterialScience Offers services on external market Turnover worldwide 400 Mill. Employees worldwide 2800 Client industries Health Care Crop Science Material Science/Polymers Chemicals BayOpX – Bayer Technology Services in Bayer

3 Indista – Dr. H. Mothes Page 3 Engineering Procurement Construction Product & Process Innovation Process Optimization Troubleshooting BayOpX – Bayer Technology Services

4 Indista – Dr. H. Mothes Page 4 BayOpX – Operational Excellence: Hype or Opportunity? Quelle: Process 12/2007

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

6 Indista – Dr. H. Mothes Page 6 BayOpX – Operational BTS Operational Excellence as an Optimization Problem: Minimize (Operational Cost) = f (Raw Materials, Energy, Personnel, Capital) Operational Excellence means superior performance executing daily business processes 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.)

7 Indista – Dr. H. Mothes Page 7 BayOpX – From Technology to Operational Excellence Products & Processes Customer Technology & Method BTS Operational Excellence requires an integrated Approach Assessment Energy Materials Assets Technology Raw Materials & Energy Savings Capacity Management Asset Management Technology Management SolutionsImplementation

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

9 Indista – Dr. H. Mothes Page 9 BayOpX – A general Methodology for Solutions Identify customers 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 Operational Excellence requires Methodology Define Measure Analyse Improve Control D M A I C

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

11 Indista – Dr. H. Mothes Page 11 BayOpX – Improvement Project Portfolio Define Measure Analyse Improve Control D M A I C BayOpX promotes profitable Projects 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 Bubble Size = Savings Potential C1 C3C2 A B Profitability Technical Feasibility 3 years ROI difficult easy not profitable

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

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

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

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

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

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

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

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

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