Challenges & solutions in organizational implementation of end-to-end ...€¦ · Challenges & success factors in integration of manufacturing excellence at the s hop floor 13.45

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Challenges & solutions in organizational implementation of end-to-end proCesses in the ChemiCal industry and impaCt on effeCtive proCess management

25th – 26th February 2013 | MaRITIM pRoaRTe hoTel beRlIn

MoRe Than 15 case sTudIes | IcebReakeR sessIon |

challenge youR peeRs | evenIng sessIon | WoRld cafÉ sessIon

2nd annual

http://manu-chem2013.we-conect.com

2nd annual Global manuchem StrateGieS 201325Th – 26Th febRuaRy 2013 | MaRITIM pRoaRTe hoTel beRlIn



oVerView2nd annual Global manuchem StrateGieS 2013

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luca Rosetto, corporate vice president corporate operations & Responsible caredsm / the netherlands

dr. dirk holbach, corporate vice president International productionhenkel ag & Co. Kgaa / germany

dr. gerhard gigl, senior vice president, head of div. launch & production site germanyBoehringer ingelheim pharma gmbh & Co. Kg / germany

gerd pösch, general Manager operations sasol o&ssasol / germany

otto schnurr, former executive board Memberineos phenol and ineos Chlorvinyls / germany+uK

Hubert Scheuermann, Chief Manufacturing Officersynthomer gmbh / germany

dr. karsten eller, cooBeckers group / germany

philipp kohn, operations network lead powder coatings eMeadupont performance Coatings emea / germany

Wolfgang laures, global supply chain & operations directoravery dennison / the netherlands

Wes oren, director global Manufacturing americas, eIMea and asiahB fuller / usa

debbie keehn, global supply chain directorCelanese Corporation / usa (tbc)

karin born, global head six sigma + lean initiative sgl excellencesgl Carbon se / germany

kief hess, director, global process safetyChemtura Corporation / usa

Marc labeille, business excellence director, engineering plastics gbu Rhodiasolvay s.a. / Belgium

dr. herbert Maier, head of global competence center energy & utilitiesClariant international ag / switzerland

klaus Weckheuer, Manufacturing directorgrace gmbh & Co. Kg / germany

John n. papageorgiou, head of engineeringlanxess rubber nv / Belgium

Thomas Walz, vice president operationsesK Ceramics gmbh & Co. Kg / germany

neil heffernan, principal consultantstroud Consulting / uK

Thorsten hofmann, partnerstroud international / germany

hans van driessche, business Improvement leader germany – ceesun Chemical nv / Belgium

dr. kristina platkowski, director operations synthetic Rubberstyron germany gmbh / germany

> operational excellence & process optimization in the chemical industry: success indicators and business enablers for plant managers and global operations responsibilities

> process excellence and business improvement in safety / regulatory, safety / production,

logistics, purchase, quality control / quality assurance and maintenance> Intelligent energy management in chemical

production: continuous, integrated strategies and systems for a holistically optimized and economical energy management> plant debottlenecking and optimization in chemical industries> lean and s&op cultural Transformation in global batch chemical Manufacturing > long term maintenance & plant asset manage-

ment development as an element of operations excellence

> strategic selection of a production site – reasons, design, roll out and conclusion > human error prevention & behavioral safety management in chemical production for sustainable manufacturing improvements> Mes as a booster of operational excellence in

Manufacturing – using automation to achieve review by exception, vertical integration of a Mes in a global & local scM and manufacturing network

> human error prevention & behavioural safety Management in chemical production for

sustainable manufacturing improvements> challenges for restructuring and site develop-

ment after a mayor acquisition> vertical & horizontal integration of Manufacturing

excellence in a scM and manufacturing network> Implementing a successful production (planning) system & integrating a global supply chain management system to manage inventory, peak demands and reduce time to market

speaKers & moderators main topiCs

Business partners

we.ConeCt business peersTake advantage of solution-oriented individual meetings that we can arrange with thesepartners before and during theconference.




aGendaicebreaKer SeSSion | sunday, 24Th febRuaRy 2013

20.00 | Round Tablespre-conference drinks and icebreaker round tables with speakers, business partners & participants

IcebReakeR Round Tablelean-Change management on a global scale and implementation on a local level – challenges & advantages for successful execution in global plant networkdebbie Keehn, global supply chain director, Celanese Corporation / usa (tbc)

we.conect icebreaKerour Icebreaker session consists of small round tables with speakers, business partners and attendees where the audience will discuss the main challenges and cutting edgetopics 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.

Contents

p. 2 | overview speakers & Moderators Main Topics

p. 3 | overview business partners icebreaker Icebreaker Round Tables

p. 4-6 | conference day 1 challenge your peers evening session

p. 6-8 | conference day 2 World café session

Business partners

travel partner

we.ConeCt business peersTake advantage of solution-oriented individual meetings that we can arrange with these partners before and during the conference.

Make excellent contacts with decision makers to expand your network and generate leads from the best contacts in the business. for further information please visit http://manu-chem2013.we-conect.com.

stroud Consultingchancery house | 53-64 chancery lane | Wc2a 1Qs london, ukphone: +44 (0)8700 102 106 | email: [email protected]

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referenCes of our past ConferenCes

“I would like to congratulate you for the professionalism of your organization and all the special sessions you organized in order to generate discussions between attendees and get to know each other.“Philippe Heim, TOTAL Refining & Chemicals / Belgium

“Very interesting, professionally organized event with competent andreally international presence!“tobias zaers, Bis / germany




aGendaconFerence day 1 | Monday, 25Th febRuaRy 2013

8.00 | Registration with coffee and tea

8.30 | Welcome and introduction by we.conecT and the chair

we.conect StrateGy tracK (1)operational excellence & process optimization in the chemical industry – success indicators and business enablers for plant managers and global operations responsibilities

8.45 | case studyChallenges in scaling down a global manufacturing excellence framework from the business side to the shop floor> how to translate a company’s business strategy into an operations’ strategy?> how to embed this operations strategy into different business units?> how to deploy the business units’ operations strategy to sites?> how to bring strategy down to the shop floor?luca rosetto, corporate vice president corporate operations & Responsible care, dsm / the netherlands

9.20 | case studymanufacturing excellence through competitive leadership: how to achieve common goals in the triangle production, quality and supply chain?> steering operational excellence > The magic triangle: productivity / supply chain / Quality> factors of change: vision – strategy – capabilities – Incentives – Resources> leading the change – change Management and sustainabilitythomas Walz, vice president operations, esK Ceramics gmbh & Co. Kg / germany

9.55 | case studya four years journey to operational excellence at the german launch & production site of Bi> productivity – flexibility – complexity: an holistic and strategic approach to operational excellence> standardized and sustainable implementation of bI lean> enhancement of flexibility and agility by strategic workforce planning> definition of complexity parameters and handling within the given conditions> critical success factors in implementing an operational excellence systemdr. gerhard gigl, senior vice president, head of div. launch & production site germany, Boehringer ingelheim pharma gmbh & Co. Kg / germany

10.30 | Refreshment break with networking Zone

we.conect StrateGy tracK (2)vertical & horizontal integration of manufacturing excellence in a sCm and manufacturing network

11.00 | case studyimprovements in production, sales & operations planning in a diversified synthomer production network > strategic alignment of business demand and production capabilities> operational excellence as a global standard> combination of high throughput and specialty production in a virtual plant> chances and risks in an after acquisition period hubert scheuermann, chief Manufacturing officer, synthomer gmbh / germany

11.35 | case studyvertical integration of an opeX & manufacturing excellence approach in a global & local sCm and manufacturing network> develop a global IT platform / IT organization in global chemical manufacturing network> Implementation of lean Manufacturing, lean Management and lean design> Integration into opeX, implementing a kpI tree to steer the sc on a cost center as well on the global sc level, Integration efforts for scM> synergy effects in the global production networkdr. philipp Kohn, operations network lead powder coatings eMea, dupont performance Coatings / germany

12.10 | case studystrategic planning and technology transfer to east-european, BriC production sites> new construction or maintaining sites?> assessment or remediation> expansion of production at the site> logistics – what is the most feasible location?tba

12.45 | lunch with networking Zone

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we.conect beSt practice tracK (1)Challenges & success factors in integration of manufacturing excellence at the shop floor

13.45 | case studyWith lean & six sigma from green field investment planning to high performance production> how lean 3p simulation allows to reduce significantly space and costs needed for investments > how six sigma successfully supports start up and flawless running of production lines> how six sigma and statistical Thinking helps to understand real customer needs and achieve cost and quality leadershipKarin Born, global head six sigma + lean initiative sgl excellence, sgl Carbon se / germany

14.20 | case study12 years of six sgima at graCe: Challenges, learnings, Kpis and success factors > program evolution: key challenges and learnings during the integration of six sigma in the operations system from different perspectives> six sigma from a product life cycle perspective: objectives, organization, focus areas, high- and lowlights at different stages> linking six sigma with Manufacturing strategies: from planning to execution> application of tools and kpIs during 12 years of six sigma: The classroom meets the factory floorKlaus Weckheuer, Manufacturing director, grace gmbh & Co. Kg / germany

14.55 | case studymanaging technical & operational issues in commissioning new process plants> safety and risk, isolation & testing> Integration of operating plant, mechanical completion and integrity checking> plant preparation and isolation, utilities and electrical system commissioning> specific equipment / commissioning issues, machinery/ rotating equipment, vessels, towers and pipe work etc.> Removal of hazardous substances and purging Instrumentation commissioningtba

we.conect beSt practice tracK (2)human error prevention & Behavioral safety management in Chemical production for sustainable manufacturing improvements

15.30 | case studysuccessful strategies for managing capital investment projects > Why are capital investment projects so important / what is at stake?> key points to get right in the early planning stages> how to manage expectations of stakeholders and leverage on roles of steering committee & project manager> portfolio management for site based capital projects> Which project organisation do you need to have in place> using project controls to effectively execute projects and work with third parties> experience from international projects John n. papageorgiou, head of engineering, lanxess rubber nv / the netherlands


16.35 | parallel Round Tables

we.conect challenGe your peerS –what would you do?based on your input we will create these Round Tables, each with one moderator.The participants interact, describe & discuss their specific issues, approaches and solutions regarding the conference topic.

we.conect beSt practice tracK (3)implementing a successful production (planning) system & integrate a global supply chain management system to manage inventory, peak demands and reduce time to market

17.35 | case studyachieving superior results through the implementation of a flexible economy adjusted production system across different regions and cultures> Implement a global and standardized a3 strategy deployment process for target setting and global alignment> how to develop a robust s&op process that flexibly reacts to local economy changes?> What are the challenges, trends and developments in each region (ap, na, la, eu) and how to address them?> how to leverage the performance review system to rate and develop the organization to achieve superior performance?Wolfgang laures, global supply chain & operations director,avery dennison / the netherlands


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18.10 | case studytaking continuous improvement to the next level transforming the organization by creating a Ci culture > how do you generate passion for continuous improvement in a large organization?> global organizations face different cultures in each region: how do you minimize the impact of this on the roll out of cI processes?> overcoming resistance to change – both from senior management and shop floor staffdr. Kristina platkowski, director operations synthetic Rubber, styron deutschland gmbh / germany

20.00 | dinner and end of day one

networKinG dInneR

8.30 | Welcome and introduction by we.conecT and the chair

we.conect Solution tracKasset management as a part of opeX

8.40 | case studyrequirements put to the test of energy reduction without investments – processes to reduce energy consumption at chemical sites> lessons learned from the lifecycle management of plants and equipment in relation to their energy consumption> global roll-out of an energy management system> continuous quality improvement processes applied to energy reduction> from quick checks and energy efficiency to a systematic and fully integrated energy management system for maximum RoI & business valuedr. herbert maier, head of global competence center energy & utilities, Clariant international ag / switzerland

9.15 | case studylong term maintenance & plant asset management development as an element of operations excellence> Maintenance excellence as one major element of operations excellence (beside energy, process control / apc and project Management)> asset strategy & asset management for improved availability, early problem detection and short maintenance downtimes> from cost cutting to long term maintenance improvement planning, maintenance excellence and overall cost reductiongerd pösch, general Manager operations sasol o&s, sasol / germany

9.50 | case studymes as a booster of operational excellence in manufacturing in our solvay gBus ex rhodiamarc labeille, business excellence director, engineering plastics gbu Rhodia, solvay s.a. / Belgium



aGendaconFerence day 2 | Tuesday, 26Th febRuaRy 2013

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we.conect world caFéthe World Café will be initiated with short statements

10.50 | short statementseach World Café moderator gives a short description of the specific Café

Short Statement strategy & Improvement café 1how does sustainability actually deliver value & how can we translate sustainable manufacturing operations into genuine business value for profitable growth?> aligning sustainable goals with corporate objectives> focusing on customer requirements to deliver sustainable products> leveraging sustainability as an entrepreneurial activity across the value chain> Implementing a sustainable thinking culture approach at the shop floordr. dirk holbach, corporate vice president International production, henkel ag & Co. Kgaa / germany

Short Statement Integration caféhow to ramp up a manufacturing excellence project and how to transfer ownership to the local management and other departments in order to mix top down & bottom up approach?hans van driessche, business Improvement leader germany – cee, sun Chemical nv / Belgium

Short Statement human error prevention caféhuman error prevention & Behavioural safety management in Chemical production for sustainable manufacturing improvementsotto schnurr, former executive board Member, ineos phenol and ineos Chlorvinyls / germany+uK

Short Statement strategy & Improvement café 2on-demand data access across chemical operations – connecting global operations> Implementing a cross-site, cross-company solution for data management during chemical manufacturing> providing centralized access to view and analyzing data on-demand> allowing manufacturing teams to collaborate effectively through effective data management> Improving process efficiency and maintaining product quality> planning & optimizing multi-purpose productionthorsten hofmann, partner, stroud international / germanyneil heffernan, principal consultant, stroud Consulting / uK

11.10 | Start world caFé part 1 | each SeSSion laStS 30-40 minuteSwe.conecT and the chair open the World café, explaining the principles and set the World café etiquette.

12.30 | lunch with networking Zone

13.30 | Start world caFé part 2 | each SeSSion laStS 30-40 minuteS

14.50 | World café panel discussionpanel discussion & summary of the World Café session trough the moderators



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Strategy & improvement café 1

integration café human error prevention café



integration café human error prevention café






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we.conect beSt practice tracK (4)plant start up, design, Commissioning & restructuring

15.40 | case studyglobal & local safety and psm rollout and integration in continuous improvement program at Chemtura> build the journey to safety excellence toward an incident free workplace> using causal Mapping to achieve through investigations> Incident sharing key to achieve safety excellence > near-Miss and leading Metrics build strong foundations for safety excellenceKief hess, director, process safety, Chemtura Corporation / usa

16.15 | case studyChallenges for restructuring and site development after a major acquisitionWes oren, director global Manufacturing americas, eIMea and asia, hB fuller / usa

16.50 | case studyexpanding your production footprint in emerging countries> setting up plants in bangladesh and nigeria> Joint-venture versus doing it alone> how to deal with issues like safety or corruption?> effective project management across the globedr. Karsten eller, coo, Beckers group / germany

17.25 | closing words from the chair and end of the conference

referenCes of our past ConferenCes

“I certainly enjoyed the sections and sessions – Top organization &conference!“Kaveh pourteymour, Bp / uK

“Great Event & Really interactive sessions!“Ben hopkins, dsm / usa

“Well organized and excellent combination of topics.“thomas gronauer, Bayer Bitterfeld gmbh / germany

“Creating new connections and expanding networks.“marc labaille, solvay / france

“Very interesting, professionally organized event with competent and really international presence!“tobias zaers, Bis / germany

“Perfect overview and multiple views!“dr. manfred selig, Wacker Chemie ag / germany

“Perfect background of participants, really advanced level!“dr. Wolfgang rybczynski, sap deutschland / germany


For more detailed inFormationabouT ouR speakeRs and InTeRacTIve segMenTs please vIsIThttp://manu-chem2013.we-conect.com

We aRe lookIng foRWaRd To WelcoMIng you!

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Challenges & solutions in organizational implementation of end-to-end ...€¦ · Challenges & success factors in integration of manufacturing excellence at the s hop floor 13.45