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Copyright © 2011 DuPont. All rights reserved. The DuPont Oval Logo, DuPont™, and The miracles of science™ are registered trademarks or trademarks of DuPont.

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Presentation on theme: "Copyright © 2011 DuPont. All rights reserved. The DuPont Oval Logo, DuPont™, and The miracles of science™ are registered trademarks or trademarks of DuPont."— Presentation transcript:

1 Copyright © 2011 DuPont. All rights reserved. The DuPont Oval Logo, DuPont™, and The miracles of science™ are registered trademarks or trademarks of DuPont or its affiliates. Achieving and Sustaining Operational Excellence in Manufacturing: DuPont Approach Srinivasan Ramabhadran Global Leader Process Safety & Risk Management Offerings DuPont Sustainable Solutions

2 Copyright © 2011 DuPont. All rights reserved. The DuPont Oval Logo, DuPont™, and The miracles of science™ are registered trademarks or trademarks of DuPont or its affiliates. 2 Safety is a DuPont Core Value Core values: Safety, ethics and respect for people and the environment $32 Billion revenue with 13 business units from electronics to plastics, paints and agricultural chemicals Over 175 operating facilities around the world Worldwide reputation for industrial safety DuPont applies a single PSM management system worldwide

3 Copyright © 2011 DuPont. All rights reserved. The DuPont Oval Logo, DuPont™, and The miracles of science™ are registered trademarks or trademarks of DuPont or its affiliates. 3 To be the world’s most dynamic science company, creating sustainable solutions essential to a better, safer, healthier life for people everywhere. We are a market-driven science company. The Vision of DuPont

4 Copyright © 2011 DuPont. All rights reserved. The DuPont Oval Logo, DuPont™, and The miracles of science™ are registered trademarks or trademarks of DuPont or its affiliates. 4 Mission: Sustainable Growth The creation of shareholder and societal value while we reduce the environmental footprint* along the value chains in which we operate. *All injuries, illnesses, incidents, waste, emissions, use of water and depletable forms of raw materials and energy. 4 ETHICS & SUSTAINABILITY

5 Copyright © 2011 DuPont. All rights reserved. The DuPont Oval Logo, DuPont™, and The miracles of science™ are registered trademarks or trademarks of DuPont or its affiliates. 5 DuPont Sustainability Accomplishments Goal achieve 5% ($50 Million USD) annual decrease in energy use, consistent with sustainability goals Results 1990 - 2009  19% decrease in energy use  20% increase in production  $5B in cost savings * TRI = Toxic Release Inventory Sources: DuPont Global Reporting Initiative (GRI) report, Yahoo Finance Reduction 1990 - 2009 Air Carcinogens92% U.S. TRI* “Releases”77% Air Toxics75% Energy Efficiency Initiatives Examples Integrated load controls Utilize Vented H2 in CB Boiler Improve Condensate Return Reduce Liquid Nitrogen Usage Steam Trap Maintenance Cooling Tower Water Temperatures Monitoring & Targeting Mindset and Behaviors… Share price ($) 100$ 1990 1995 2000 2005 2009

6 Copyright © 2011 DuPont. All rights reserved. The DuPont Oval Logo, DuPont™, and The miracles of science™ are registered trademarks or trademarks of DuPont or its affiliates. 6 DuPont Approach Major Shift in Leadership Thinking Sustainable growth is rooted in core values, driven by leadership commitment, aligned with business objectives, and embedded throughout the organization and culture. Compliance & Reporting Initiatives Strategy & Roadmap Growth & Innovation Operations Efficiency Integrated Management Systems Culture & Processes in Operations Management Stakeholders Engagement Corporate Core Values Shift emphasis from here To here

7 Copyright © 2011 DuPont. All rights reserved. The DuPont Oval Logo, DuPont™, and The miracles of science™ are registered trademarks or trademarks of DuPont or its affiliates. 7 Assets Management Integrated Production Systems Outcomes and Sustainable improvemen ts Plant Performanc e and business imperatives Manufacturing Asset Managing Process  DuPont Best Practices  Standard Operational Procedures  DuPont Best Practices  Standard Operational Procedures Technical Model  Operate to Plan ( Capacity, Productivity)  Maintenance and Reliability  Supply Chain  Manufacturing Technology  Small Project Implementation  Operate to Plan ( Capacity, Productivity)  Maintenance and Reliability  Supply Chain  Manufacturing Technology  Small Project Implementation Capabilities Engine  200 yrs of Manufacturing Experience  DuET  Engg. COC – M & R, Energy  Six Sigma Champions  Subject Matter Experts  200 yrs of Manufacturing Experience  DuET  Engg. COC – M & R, Energy  Six Sigma Champions  Subject Matter Experts Mindsets and Behaviors  Technical training  Continuous Learning Environment  Technical training  Continuous Learning Environment Production Goals integrated with Sustainability Goals

8 Copyright © 2011 DuPont. All rights reserved. The DuPont Oval Logo, DuPont™, and The miracles of science™ are registered trademarks or trademarks of DuPont or its affiliates. 8 Process Safety Management Defined Process Safety Management is the application of management systems and controls (standards, procedures, programs, audits, evaluations) to a manufacturing process in a way that process hazards (risks) are identified, understood and controlled so that the process related injuries and incidents are prevented. This requires a sustained effort by leadership at all levels.

9 Copyright © 2011 DuPont. All rights reserved. The DuPont Oval Logo, DuPont™, and The miracles of science™ are registered trademarks or trademarks of DuPont or its affiliates. 9 DuPont Process Safety Management Model

10 Copyright © 2011 DuPont. All rights reserved. The DuPont Oval Logo, DuPont™, and The miracles of science™ are registered trademarks or trademarks of DuPont or its affiliates. 10 PSM Leadership Model Trained, Knowledgeable, Capable People in all roles Adequate resources Financial Support Knowledge Management Cat A PSM Incidents Cat C PSM Incidents/Near misses/ Key Learnings Metrics & Recommendations from Incidents, PHA & Audits Leadership Safety Culture, Commitment, Accountability, Resources, Involvement Foundational Cat B PSM Incidents Lagging Indicators Leading Metrics

11 Copyright © 2011 DuPont. All rights reserved. The DuPont Oval Logo, DuPont™, and The miracles of science™ are registered trademarks or trademarks of DuPont or its affiliates. 11 Achieving Operational Excellence: Leadership driven Objective Detail Future “TO-BE” Objective Culture Maturity curve Safety Focus Areas (Safety elements, timing, milestones) Implementation Plan Actions to upgrade upstream Safety operating model Strategy Overall “AS-IS” Position Culture Maturity curve Executive Summary Key Risks Gaps & best practices Detailed Analysis Findings Focus Areas

12 Copyright © 2011 DuPont. All rights reserved. The DuPont Oval Logo, DuPont™, and The miracles of science™ are registered trademarks or trademarks of DuPont or its affiliates. 12 Compliance assurance: Line Accountability Tasks & Deliverables Visible program support Strategic guidance, direction & objectives Hold HSSE councils, Cross-sub working groups to commitments Supporting Orgs Technical guidance Feedback & testing Ongoing support Project Team Day-to-day management Project communications Information clearinghouse Cross-sub working groups Design & validate policies and processes Develop rollout materials and plans Manage implementation planning and execution Ongoing performance monitoring Process adjustment and refinement Technical guidance Feedback & testing Line Organization Implement policies, procedures and processes Ensure appropriate training and execution Provide data to subcommittees for ongoing monitoring HSSE Experts Line organization Supporting Implementing Workplace Safety Process Safety Contractor Safety Occupational Health Environment CSC Chair HSE Council Security Project Team` Cross-subsidiary working group

13 Copyright © 2011 DuPont. All rights reserved. The DuPont Oval Logo, DuPont™, and The miracles of science™ are registered trademarks or trademarks of DuPont or its affiliates. 13 Practical approach to establish new practices and behaviors Coaching Practical Application client lead & Dupont review Practical Application DuPont lead Content Finalization through task teams Workshop 1Workshop 2Workshop 3 Practical Application client lead & Dupont support Performance metrics to sustain change Deliver Top management involvement Transformation Practical Application: Skills transfer is tested and coaching is provided in the field Experiential workshops: Formal classroom sessions focused on knowledge transfer & skill development related to skills needed to drive the change program. Sessions provide the conviction and motivation for the change program. Performance metrics to sustain change: Selecting and implementing performance metrics with a focus on leading metrics to sustain the improvement initiatives. Expert and Experiential coaching: On-the-job coaching to build capabilities and confidence to drive the change. Content finalization through task teams: Development of best practice Management System and content.

14 Copyright © 2011 DuPont. All rights reserved. The DuPont Oval Logo, DuPont™, and The miracles of science™ are registered trademarks or trademarks of DuPont or its affiliates. 14 Focus on Execution is Key = Management Standards Operational Discipline Operational Excellence x

15 Copyright © 2011 DuPont. All rights reserved. The DuPont Oval Logo, DuPont™, and The miracles of science™ are registered trademarks or trademarks of DuPont or its affiliates. 15 Operational Discipline Characteristics OPERATIONALEXCELLENCE Leadership by Example ExcellentHousekeeping EmployeeInvolvement PSRMResources OrganizationalPride NoShortcuts ActiveCommunications Practices=Procedures Up-To-DateDocumentation StrongTeamwork SharedValues

16 Copyright © 2011 DuPont. All rights reserved. The DuPont Oval Logo, DuPont™, and The miracles of science™ are registered trademarks or trademarks of DuPont or its affiliates. 16 Leadership Responsibilities for Sustenance Leaders must have a clear vision of the ultimate goal of the company’s process safety management efforts Leaders must set the goals and strategic objectives Leaders must insure sufficient, quality resources are dedicated to PSM system requirements Leaders must hold their line organization accountable for PSM implementation and results. Leaders must recognize and reward PSM accomplishments to drive continuous improvement Leaders must lead…felt leadership

17 Copyright © 2011 DuPont. All rights reserved. The DuPont Oval Logo, DuPont™, and The miracles of science™ are registered trademarks or trademarks of DuPont or its affiliates. 17 Conclusion Process Safety Management is the way to deal with the most serious and challenging business risks to achieve operational excellence Structured and systematic managing processes and systems, high standards of performance, tracking results of key metrics and audit will help sustain operational excellence It provides an opportunity to prevent a catastrophic incident from occurring PSM. Live it. Lead it.

18 Copyright © 2011 DuPont. All rights reserved. The DuPont Oval Logo, DuPont™, and The miracles of science™ are registered trademarks or trademarks of DuPont or its affiliates. 18 www.sustainablesolutions.dupont.com For further information, please contact: Ramabhadran.Srinivasan@sgp.dupont.com Mun-Loong.Yau@sgp.dupont.com


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