Review 2012: http://manu-chem2013.we-conect.com/ GLOBAL MANU CHEM STRATEGIES 2012 Improvements in chemical manufacturing in a changing business environment 2012 will be probably one of the most difficult years to forecast for some time. Concerns remain about the changing business environment and the slowdown in the global economy. Global competition, maturing markets, over-capacity plants, increasing environmental pressure, and rising raw material prices continue to challenge the profitability of the chemical-industry. Customers are demanding lower prices and increased service levels, while competitors are getting smarter, leaner and expanding their global reach. New product lifecycles are shorter and competitors are entering the market faster. Energy and raw material costs have exhibited extreme volatility. Globalization is lengthening supply chains and increasing business complexity, while increased government regulation and scrutiny and greater product stewardship are increasing the amount of information required in the chemical supply chain, often at significant cost. A suite of (software) tools & methods, such as MES, BI or an integrated automation infrastructure has been developed in order to fulfil both the technical and human requirements of achieving operational excellence. This emerging technology is available today and can be implemented to provide companies in the chemical industry with capabilities that improve visibility, manage events, and provide performance scorecarding and analytics for improving and understanding performance. This allows production and logistics processes to be synchronised so that, at any time, products are quickly and cost efficiently delivered which contributes to maintaining a competitive edge. Many leading chemical manufacturers recognize the need for a vastly improved and more global automation infrastructure than currently exists in even the most automated facilities. These companies need better tracking and tracing capabilities, cost-effective production management solutions, methods to maximize asset utilization and solutions for improving quality and safety. Agile enterprise is always one step ahead of the competition, which cultivates a responsive environment and delivers major improvements in lead time, product quality, and lower production costs. The resulting increase in inventory levels, costs and savings, and the massive pressure from Asian competitors requires a thorough discussion of methods and tools to implement a strategic and sustainable production management in the chemical industry under the impact of global shifts in the market. The “Global ManuCHEM Strategies” will discuss these challenges and solutions with top executive and managers from all leading chemical companies from Europe and the US. We look forward to welcoming you! Your we.CONECT team

1. Global
Manu Chem
Strategies 2012
Strategic Challenges for manufacturing
excellence and process safety in
chemical operations
13 TH – 14 TH February 2012 | Swissôtel Berlin
17 Case Studies | 3 World CafÉs | Icebreaker Session |
Challenge your Peers
http://manu-chem.we-conect.com
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2. Global ManuChem Str ategies 2012
13 TH – 14 TH February 2012 | Swissôtel Berlin
Content Overview OVerview
P. 2-3 | Overview
Global ManuChem Strategies 2012
Key Topics
Speakers
Business Partners Key topics SPeakers
Media Partners
> Operational excellence & process optimisa- Kaveh Pourteymour
Participants CIO – Global Refining and International Businesses
tion in the chemical industry: Success
BP / UK
indicators and business enablers for plant
P. 4 | Icebreaker Session
managers and global operations executives Conor Troy
Internal Business Manager
> Manufacturing Excellence through Safety
P. 6 | Conference Day 1 Symrise AG / Germany
Challenge your Peers Leadership – HSE, Human Behaviour &
Pieter Verberne
Evening Session Process Safety for achieving excellence in General Manager Energy
chemical operations AkzoNobel Industrial Chemicals / Netherlands
P. 7 | Conference Day 2 > Vertical integration of a MES in a global & Bernhard Thier
World Café local SCM and manufacturing network Responsible Care Manager
> Intelligent energy management in chemical Cefic / Germany
production: Continuous, integrated strategies Philippe Heim
and systems for a holistically optimized and HSE-Manager Safe Conduct of Operations
TOTAL Refining & Chemicals / Belgium
economical energy management
> Implementing a successful production Dr. Max Schlumpf
CTO
planning system & integrate a global supply Holcim Ltd. / Switzerland
chain management system to manage
Gareth McAllister
inventory and reduce time to market European Business Director & Managing Director
> Total Plant Asset Management Systems – LORD Germany
Concept of a comprehensive asset LORD Suisse Sarl / Switzerland
management Dr. Wolfgang Rybczynski
> Implementing a sustainable continuous Principal Business Consultant, Business
Transformation Services
improvement culture in plant operations Andreas Rizzetti
> Challenges in reaching Operational Solution Architect, Industry Solutions
Excellence – Global IT infrastructure as a Process&LifeScience
SAP Deutschland AG & Co. KG / Germany
business enabler for reliable, safe and
Jean-Marc Delbos
efficient manufacturing operations Industry Principal for Chemicals, SAP EMEA
SAP FRANCE S.A. / France
Marco van Veen
Business Process Integration
BUSINESS PARTNERS Endress+Hauser / Germany
Michael Faber
Head of Production Excellence Europe
BASF Coatings GmbH / Germany
Ashish Shah
Project Director
Fluor Corporation / USA
Gert Smit
Senior Process Director
Fluor Corporation / Netherlands
Thomas Gronauer
Head of Project Management Office / Operational
Excellence
Bayer Bitterfeld GmbH / Germany
Shashank Shah
Senior Principal Engineerinig Leader
Arkema Inc. / USA
Ben Hopkins
MEDIA PARTNERS Site Director
DSM / USA
Christian Rieß
Location Leader
Borealis Polymere GmbH / Germany
Andreas Speh
SHE Leader
DuPont Performance Coatings GmbH / Germany
Dr. Gunther Walenta
Head of the CO2 Project
Lafarge Research Centre / France
Dr. Manfred Selig
Director Change Management &
Technical Scout
Wacker Chemie AG /
Germany
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3. Global ManuChem Str ategies 2012
13 TH – 14 TH February 2012 | Swissôtel Berlin
OVerview
Global ManuChem Strategies 2012
Business Partners
Endress+Hauser Messtechnik GmbH+Co. KG
Colmarer Straße 6 | 79576 Weil am Rhein, Germany
Phone: +49 (0)7621 9 75 01 | Fax: +49 (0)7621 9 75 55 5
Email: info@de.endress.com
www.de.endress.com
SAP Deutschland AG & Co KG
Hasso-Plattner-Ring 7 | 69190 Walldorf, Germany
Phone: +49 (0)6227 7-47474 | Fax: +49 (0)6227 7-57575
www.sap.com
Stork Technical Services B.V.
Van Deventerlaan 121 | P.O. Box 2776, 3500 GT, Utrecht, The Netherlands
Phone: +31 (0)30 6691700 | Fax: +31 (0)30 6664733
Email: info.storktechnicalservices@stork.com
www.storktechnicalservices.com
we.CONECT business peers
Take advantage of solution-oriented individual meetings that we can arrange with these partners before and during the
conference.
Who participates?
Executives of the Board, Managing Directors and Managers from the following departments:
> Production / Manufacturing > Manufacturing Business Systems
> Process Control / Production Control > Automation / Process Automation
> Planning > Manufacturing IT / MES
> Process Excellence / Six Sigma / OPEX / Lean > Technical Services
> Continuous Improvement > Risk / EHS / Energy
> Maintenance / Reliability > Technical Operations / Technical Engineering
> Plant Start-up & Commissioning
> Contractors / Equipment Specialists from all chemical, petrochemical
> Operations and chemical industry related
> Supply Chain companies across the globe
from following industries:
> Base Chemicals > Polymers
> Inorganic industrial > Elastomers
> Organic industrial > Pleochemical
> Ceramic products
> Petrochemicals and all other chemical and petrochemical corporates
> Agrochemicals
Demographics:
Netherlands, Germany, Belgium, UK ,Sweden, Norway ,Finland ,Ireland ,Austria ,Switzerland ,Italy ,France ,Spain, Poland,
Hungary, Turkey ,USA ,Russia
Media Partners
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4. Global ManuChem Str ategies 2012
13 TH – 14 TH February 2012 | Swissôtel Berlin
aGENDA
ICEBREAKER Session | Sunday, 12th February 2012
we.CONECT ICEBREAKER
Our Icebreaker Session consists of small Round Tables with speakers, business partners
and attendees where the audience will discuss the main challenges and cutting edge
topics of the conference in a relaxed atmosphere. Glass in hand, make your way around
our Round Tables and get to know each other. Enjoy food and drinks at the opening of the
conference, break the ice and get the show on the road.
19.30 | we.CONECT ask the leaders
Pre-conference drinks and Icebreaker Round Tables with speakers, business partners & participants
ICEBREAKER Round Table 1
Taking Continuous Improvement to the next level Transforming the organization by creating a Continuous
Improvement culture
> How do you generate passion for Continuous Improvement in a large organisation?
> Global organisations face different cultures in each region. How do you minimise the impact of this on the roll out of
Continuous Improvement processes?
> Overcoming resistance to change ‒ both from senior management and shop floor staff
> Successful strategies for implementing Continuous Improvement
Thomas Gronauer, Head of Project Management Office / Operational Excellence, Bayer Bitterfeld GmbH / Germany
ICEBREAKER Round Table 2
Making “Green Pay”: Justifying investment in environmentally friendly processes
> Measuring your carbon footprint is not an easy task
> Defining the ‘scope’ for improvement
> Moving forward and keeping momentum
Pieter Verberne, General Manager Energy, AkzoNobel Industrial Chemicals / Netherlands
FOR 99 EUROS TRAVEL CONVENIENTLY BY TRAIN TO THE
we.CONECT EVENT
In cooperation with we.CONECT Global Leaders GmbH and Deutsche
Bahn you can travel safely and conveniently to the we.CONECT event!
The price for your Event Ticket for a return trip* is:
2nd class 99 Euros | 1st class 159 Euros
Our call centre will be happy to inform you about the ticket price for
international journeys.
To book call +49 (0)1805 - 31 11 53** and quote “we.CONECT“ as reference.Please have your credit card ready.
* An advance booking of at least three days is required. Changes and reimbursement before the first day of validity are 15 Euros excluded from the first
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For a supplement _ f 30 Euros full flexible tickets are also available for domestic travels within Germany.
o
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5. Global ManuChem Str ategies 2012
13 TH – 14 TH February 2012 | Swissôtel Berlin
aGENDA
Conference Day 1 | Monday, 13th February 2012
8.00 | Registration with coffee and tea
8.45 | Welcome and introduction by we.CONECT, from the Chairman and the Advisory Board
Chairman: Dr. Wolfgang Rybczynski, SAP Deutschland AG & Co. KG / Germany
we.CONECT Strategy Track
Operational excellence & Process optimization for the chemical industry – Success
indicators and business enablers for plant managers and global operations responsibilities
9.00 | Keynote
Challenges in reaching Operational Excellence – Global IT infrastructure as a business enabler for reliable,
safe and efficient manufacturing operations
> IT as a business enabler supporting the company’s change-program
> How to realise “Robust flexibility“in a complex technical environment and in a global SCM and manufacturing network
> Supporting Continuous Improvement Processes with standardized and safe IT Infrastructure
> Develop a global IT platform / IT Organisation
> Integration into ERP and OPEX
> Synergy effects in the global production network
> Functional Safety through Process Control Engineering, MES & Automation
> Cost / Benefit / Challenges
Kaveh Pourteymour, CIO – Global Refining and International Businesses, BP / UK
9.40 | Case Study
Approaches in delivering operational excellence for reaching an local (plant based) operational excellence
culture in global manufacturing network
> OPEX Enablers & OPEX Processes
> Excellence as a mindset: Process, people and engagement
> Implementation of operational excellence at the shop flor as in the operational business and implementation of a
sustainable „culture opex“: Pitfalls and learnings
> What is needed to get a continuous and sustainable management as part of Opex and to live the corporate culture?
Christian Rieß, Location Leader, Borealis Polymere GmbH / Germany
10.20 | Case Study
European integration approach of Production Excellence at BASF Coatings GmbH
> The European challenge
> Production Excellence System Audit
> Sustainability condition by staffing structure
> The key: Understanding Waste and Losses (Muda)
> Value Stream Mapping in Batch Production
Michael Faber, Head of Production Excellence Europe, BASF Coatings GmbH / Germany
11.00 | Refreshment break with Networking Zone
we.CONECT Best Practice Track (1)
HSE & Human Behavior & Process Safety for reaching excellence in chemical
manufacturing operations
11.30 | Case Study
Some Tools to achieve Safety Excellence in Conduct of Operations in High Risk plants
> Overview of main root causes of high potential incidents.
> Why and how determine the criticality of operations. How develop efficient operating procedures according to their
criticality.
> “Our HSE behavior standard”: A tool for people to gain a robust safety culture by demonstrating the right behaviors
> “The 12 golden rules”: A reemphasis program on basic rules that everyone must know and apply
Philippe Heim, HSE-Manager Safe Conduct of Operations, TOTAL Refining & Chemicals / Belgium
12.10 | Case Study
Manufacturing Excellence through Safety Leadership
> SHE implementation to provide a positive impact to the three core processes (the people process, the strategy
process, and the operations process), ultimately resulting in manufacturing execution excellence
> Developing a culture of SHE First at all levels in an organization requires the correct view of safety and if properly
implemented and maintained produces a positive change to the overall manufacturing operation
> People are your greatest asset, so bet on people not on strategies
> Hire, develop and retain top talent for mfg. success- people to fit the culture
Ben Hopkins, Site Manager, DSM / USA
12.50 | Lunch with Networking Zone
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6. Global ManuChem Str ategies 2012
13 TH – 14 TH February 2012 | Swissôtel Berlin
aGENDA
Conference Day 1 | Monday, 13th February 2012
14.00 | Solution Study
Simplify your Life in Manufacturing
> Managing “big data” in real-time
> Integrating Manufacturing and Enterprise
> How Mobility supports Chemical Operations
> Examples based on latest SAP Technology
Dr. Wolfgang Rybczynski, Principal Business Consultant, Business Transformation Services, SAP Deutschland AG &
Co. KG / Germany
Andreas Rizzetti, Solution Architect, Industry Solutions Process&LifeScience, SAP Deutschland AG & Co. KG / Germany
Jean-Marc Delbos, Industry Principal for Chemicals, SAP EMEA, SAP FRANCE S.A. / France
we.CONECT Solution Track (1)
Energy management and Energy efficiency in chemical manufacturing
14.40 | Case Study
Improving sustainability and efficiency in energy intensive processes
> Pricing power. How raising energy costs trigger new directions.
> Hedging future energy costs by broadening your fuel mix
> CO2-reduction may not always shield for CO2-costs
> How costs create awareness that create efficiency
> Using Lean Six Sigma for continuous improvements
Pieter Verberne, General Manager Energy, AkzoNobel Industrial Chemicals / Netherlands
15.20 | Case Study
Innovating to reduce the carbon footprint of cement production
Dr. Gunther Walenta, Head of the CO2 Project, Lafarge Research Centre / France
16.00 | Refreshment break with Networking Zone
we.CONECT Challenge your peers –
What would you do?
16.30 | Parallel Round Tables
Based on your input from the delegate checklist, we will create a round table session involving
an interactive discussion with your peers. The topics that will be discussed on-site will be
announced 3 weeks before the event begins.
Round Table 1
Continous Improvement, OPEX, Lean-, Site Performance-, Restructuring-, & Change Management in chemical plants
Ashish Shah, Project Director, Fluor Corporation / USA
Round Table 2
Challenges in Safety, HSE, Behavioral Safety & Human Error Preventions
Ben Hopkins, Site Manager, DSM / USA
Round Table 3
SCM & OPEX, Procurement Strategies, Demand & Producton Planning tools and processes for increasing
productivity and saving costs
Dr. Max Schlumpf, CTO Central Europe, Holcim Ltd. / Switzerland
18.00 | Solution Study
Resonsible Care: The manufacturers‘ perspective
> Responsible Care Introduction
> Responsible Care Tools for SMEs
> New priorities: Process Safety & Security
> Global Product Strategy & Cooperation with UNEP
> Responsible Care Worldwide
Bernhard Thier, Responsible Care Manager, Cefic / Germany
18.40 | Case Study
Step by step developing and implementing a SHE culture project
> Analyse of cultural situation after acquisition and two major incidents
> Define path forward and develop action plan
> Implementing DuPont PSM System
> Overview about actual situation and further steps
Andreas Speh, SHE Leader, DuPont Performance Coatings GmbH / Germany
DAY ONE DINNER | Restaurant SACHS
20.00 | Networking Dinner in a relaxed atmosphere to conclude the first conference day
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7. Global ManuChem Str ategies 2012
13 TH – 14 TH February 2012 | Swissôtel Berlin
aGENDA
Conference Day 2 | Tuesday, 14th February 2012
8.30 | Welcome and introduction by we.CONECT, from the Chairman and the Advisory Board
Chairman: Dr. Wolfgang Rybczynski, SAP Deutschland AG & Co. KG / Germany
9.00 | Case Study
Driving Plant Performance through Design Lifecycle Data Integration
> Design lifecycle data flow
> Single point data entry
> Data handover to OO for O&M
> Smoother plant start-up
Ashish Shah, Project Director, Fluor Corporation / USA
Gert Smit, Senior Process Director, Fluor Corporation / Netherlands
we.CONECT World Café
In the context of collective intelligence executives will work in moderated and focused small
groups (up to 12 Managers) in a relaxed, café-like atmosphere.
The we.CONECT world café will be initiated with three lectures lasting 10 minutes.
9.50 | Best Practice Café I
Symchronize – How to optimize the extended supply chain & how to build a TPM Network
> There are plenty of opportunities for improvement at the interfaces
> Collaboration along the Extended Supply is the only way to achieve the goals ahead
> SYMCHRONIZE is a business approach rather then a SC initiative
Conor Troy, Internal Business Manager, Symrise AG / Germany
10.00 | Solution Café
Information is the key ‒ but how to get it? ‒ Business process integration as a framework for integrating asset
information
> Energy management to increase energy efficiency
> Vendor managed inventory to reduce the working capital and to ensure availability
> Field data integration in ERP system as a part of plant asset management
> Smart signals from reliable field instruments into business systems
Marco van Veen, Business Process Integration, Endress+Hauser / Germany
10.10 | Best Practice Café II
World Class Manufacturing in Chemical and Petrochemical industries: What does it look like and what are the
future challenges?
> Aspects of world class manufacturing
> Implementing energy monitoring with the power of operations feeback
> Aggressively applying energy integration technologies
> Importance of an innovation culture
Shashank Shah, Senior Principal Engineerinig Leader, Arkema Inc. / USA
10.20 | START WORLD CAFÉ | EACH SESSION LASTS 40 MINUTES
we.CONECT and the chair open the World Café, explaining the principles and set the World Café etiquette.
Best Practice Café I Solution Café Best Practice Café II
12.20 | Lunch with Networking Zone
world Café Panel Discussion
13.40 | Discussion
Presentation of the key results of the World Café and the individual interview
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8. Global ManuChem Str ategies 2012
13 TH – 14 TH February 2012 | Swissôtel Berlin
aGENDA
Conference Day 2 | Tuesday, 14th February 2012
we.CONECT Solution Track (2)
Restructuring & reorganisation of manufacturing facilities
14.10 | Case Study
Restructuring & reorganisation of manufacturing facilities in alignment with new business objectives –
A turnaround to sustainable profitability
> Redefining the business model at the strategic and local plant site
> Safety culture improvement and its role in supporting turnarounds
> Defining a new quality approach
> Lean & Six Sigma – Management of people & behaviour
> Process control and information systems
> Cultural changes required to effect sustainable improvement
Gareth McAllister, European Business Director & Managing Director LORD Germany, LORD Suisse Sarl / Switzerland
we.CONECT Best Practice Track (2)
Total Plant OPEX Integration
14.50 | Case Study & Live Demo
How to deal with ISO Systems and Audits in the daily manufacturing business
> Theory versus practice
> Looking back or challenging the future?
> The value added of a certification for quality on the floor
> The change ISO management approach
> Managing technical & operational issues in commissioning new process plants
> Implications for manufacturing excellence
Dr. Max Schlumpf, CTO Central Europe, Holcim Ltd. / Switzerland
15.30 | Refreshment break with Networking Zone
16.00 | Case Study
10 years Wacker Operating System – Challenges in implementing a common and sustainable lean
manufacturing excellence
> To thrive under globalization conditions an average 7% productivity gain/y is a must
> Long term top down organizational commitment to the subject ‘productivity’ is crucial
> Buzz words MUST change in a 3-5 years rhythm, the base target ‘productivity’ must not.
> If you just adopt the main stream buzz words you follow – you do not excel
> Technical expertise is the prerequisite, change management is the key to success
> Consultants may give advice, the cure is your responsibility
Dr. Manfred Selig, Director Change Management & Technical Scout, Wacker Chemie AG / Germany
16.40 | Case Study
What differs “Manufacturing Strategy Deployment” from “Operational Excellence” projects?
> Linking manufacturing strategy and Operational Excellence activities
> The sin of Operations Management: loss of entrepreneurship
> The ultimate OE project sponsor: Your customer!
Thomas Gronauer, Head of Project Management Office / Operational Excellence, Bayer Bitterfeld GmbH / Germany
17.20 | Closing words from the chair and end of the conference
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9. For more detailed information
about Our speakers and interactive segments
please visit
http://manu-chem.we-conect.com
We are looking forward to welcoming you!
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