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

2. Group Management Board
BayOpX – Bayer Technology Services in Bayer
Offers services on external market
Turnover worldwide Mill. €
Employees worldwide
Client industries
Health Care
Crop Science
Material Science/Polymers
Chemicals
Holding Company
Group Management Board
Corporate Center
Bayer AG
Business Areas
Service Areas
Bayer
HealthCare
Bayer
CropScience
Bayer
MaterialScience
Bayer Business Services
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?
BayOpX – Operational Excellence: Hype or Opportunity?
Quelle: Process 12/2007

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

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

8. BayOpX – Operational Excellence @ BTS - Approach
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. BayOpX – A general Methodology for Solutions
BayOpX – A general Methodology for Solutions
Define
Measure
Analyse
Improve
Control D M A I C
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
Operational Excellence requires Methodology
Hier der übliche Projektablauf dargestellt in Analogie zum Six Sigma Konzept

10. BayOpX – Energy Audit / Climate Check Methodology
BayOpX – Energy Audit / Climate Check Methodology
Equipment Check
Operational Improvements
Process Control & Automation
Heat Integration & Heat Recovery
Process Improvements
Energy & Utility Systems
Facility Check / Buildings
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. BayOpX – Improvement Project Portfolio
BayOpX – Improvement Project Portfolio
Define
Measure
Analyse
Improve
Control D M A I C
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 C3 C2 A B
Profitability
Technical Feasibility
3 years
ROI
difficult
easy
not
profitable
BayOpX promotes profitable Projects

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

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

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

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

16. BayOpX – Risk Based Asset Management Methodology
BayOpX – Risk Based Asset Management Methodology
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
KPI’s
Benchmark of comparable units
Inspection/ Maintenance Score Card
Identify gaps & opportunities
BayOpX enables Asset Management Solutions
Analysis
Idea Generation
Assessment
Implementation
Sustainability D M A I C

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

19. BayOpX – Project Experience and Results
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.com www.bayertechnology.com