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Changing viewpoints of engineering as a career path, generational priorities, and global competition affect the ability of oil and gas companies to recruit, retain, and develop process engineering talent. The coming retirement of an experienced generation, along with the entrance of new engineers into the work force, creates an industry-wide experience gap, and other industry challenges require companies to better utilise process engineering skill sets. Ultimately, an effective Process Engineering Best Practice standard promotes a safe, reliable, and profitable workforce. View now to learn more! Webinar presented by Robert Ohmes: Robert is a principal consultant at KBC and licensed professional engineer in Louisiana. His primary responsibilities are centred on profit improvement initiatives, hydroprocessing unit consulting, and organisational consulting for domestic and international clients. Prior to joining KBC, Ohmes worked as a refinery engineer for Koch Refining Co. in Corpus Christi, TX.
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© 2012 KBC Advanced Technologies plc. All Rights Reserved.
Developing and Enabling the Next Generation of Process Engineers Webinar Presented by Robert Ohmes
17 July 2012
Agenda • Background • Methodology
−Aspects of Effective Performance −Process Engineering Best Practice Standard
Methodology • Summary
17 July 2012 2 PROPRIETARY INFORMATION
Background
• Refining and Petrochemical Industries facing several engineering staffing and talent challenges − Increased public scrutiny −Regulatory oversight −Experience and knowledge retention −Demographic changes −Generational traits
17 July 2012 3 PROPRIETARY INFORMATION
Demographic Shifts
Source: SBC O&G HR Benchmark 2010
17 July 2012 4 PROPRIETARY INFORMATION
Generational Traits Baby Boomers
(~1946 – 1965)
Generation X
(~1965 – 1980)
Generation Y, or Millennials
(~1981 – 1995) Company Loyalty Team Collaboration Work/Life Balance
Pay Dues Organizational Values More Information Employment Stability Performance Based
Recognition and Rewards Clear, Continuous
Performance Feedback Classic Work Ethic Flexible Work Schedules Greater Involvement Prestigious Titles Individual Career
Progressions
Professional Connections Technology Centric and Savvy
Longer Term Compensation/Benefits
Lower Level of Mechanical Aptitude
17 July 2012 5 PROPRIETARY INFORMATION
Learning Pyramid
17 July 2012 6 PROPRIETARY INFORMATION
Process Engineering Best Practice Standard • One solution: Develop and utilize a Process
Engineering Best Practice Standard • What is a Standard?
− Guiding system and philosophy − Summarizes work processes/practices, tools, accountabilities − Defines how Process Engineers will function and interact in the
organization − Provides mechanisms for talent and knowledge development and
retention
Remainder of presentation focuses on methodology to develop and utilize standard
17 July 2012 7 PROPRIETARY INFORMATION
Key Components of Effective Performance
Information and Tools
People
Work Processes and Training
17 July 2012 8 PROPRIETARY INFORMATION
Organizational Alignment
17 July 2012 9 PROPRIETARY INFORMATION
Organizational Alignment
17 July 2012 10 PROPRIETARY INFORMATION
Development Path
17 July 2012 11 PROPRIETARY INFORMATION
Assessment • Goal: Clear understanding of how the people, tools, and
work processes are functioning within the organization • Tips
− Utilize a cross functional assessment team − Focus the team on making the assessment impartial, objective,
fact-based, and transparent − Communicate the results and findings after the assessment − Consider including an external 3rd party in the assessment team − Focus on tools, information, work processes, and organizational
structure − Interview members of Process Engineering team, as well as key
customers or users of their services
17 July 2012 12 PROPRIETARY INFORMATION
Strategic Goals, Team Alignment, and Role Alignment • Strategic Goals
− Utilize existing or update via facilitated session
• Team Alignment: Develop Team Charter − Team Charter Content
o Team purpose and goals o Roles and organizational structure o Key responsibilities and accountabilities o Interfaces within and external to the team
• Role Alignment: Update or Develop Role Profile − Role Profile Content
o Detailed responsibilities aligned with overall role accountabilities o Knowledge, skills, and attributes needed to fulfill the role o Behavioral indicators needed to measure performance against the
expectations of the role 17 July 2012 13 PROPRIETARY INFORMATION
Standard Context Definition
17 July 2012 14 PROPRIETARY INFORMATION
Example System/Process/Practice
Daily Operations Support
Daily OperatingInstructions,
Planning, and Scheduling
Troubleshooting and Abnormal Situation
Management
Unit MonitoringAnd Health
Assessment
Benchmarking/Gap Analysis
ConstraintManagement
KPI
Monitoring Tooland Process
BP TechnologyManual
TroubleshootProtocol
TroubleshootGuidelines
TechnologyTraining
OIW Develop. and Audit
ConstraintMan. Process
Plan/Sch.Input Process
Plan/Sch.Translation
Process
Plan/Sch.Feedback Process
Daily Op.Instruct. Process
DAILY OPERATIONS SUPPORT PROCESSES AND PRACTICES
QualityControl
17 July 2012 15 PROPRIETARY INFORMATION
Standard Development • Standard Development
−Cataloguing − Initiative Framework Definition −Execution
• Prepare Initiative Frameworks −Need one for each “project”
• Initiative Areas −Tool Development/Refinement −Work Process Optimization −Progression Path
17 July 2012 16 PROPRIETARY INFORMATION
Tool Development • Most organizations struggle with tools due to:
−Lack of standardization −Minimal maintenance −Not “fit-for-purpose” −Lack of training and support
• Example Process Engineering Tools −Unit Monitoring Applications −Benchmarking/Gap Analysis −Technology Manuals
17 July 2012 17 PROPRIETARY INFORMATION
Unit Monitoring Applications • UMA Tool Capabilities
− Link directly to process/lab historian − Complete material balance and any
necessary quality checks on resulting balance
− Generate KPIs that are useful to Engineering, Operations, Planning, and Reliability staff
− Provide summaries of key results (Dashboards, Tables, Charts, Graphs, etc)
− Standard platform and similar look/feel across all units
− Tool maintenance process and capability built-in
17 July 2012 18 PROPRIETARY INFORMATION
Benchmarking/Gap Analysis • Traits of good benchmarks
− Criticality for safe, reliable, and profitable unit operation − Measureable, realistic, reconciled, and dynamic − Common understanding and language − User level and function appropriate − Actionable
• Typically organized in KPI Tree • Results often fed to UMAs • Development options
−Operations/Engineering −Sister plants −3rd Parties
17 July 2012 19 PROPRIETARY INFORMATION
Technology Standards • Technology Standards drive knowledge retention and
transfer • Process Engineer’s handbook
− Technology specific − Compare unit to benchmark − Troubleshooting guides − Procedures to resolve out-of- range performance
• Traits of Effective Standard − Targeted and useful − Broad acceptance − Tailored to facility − “Evergreen”
17 July 2012 20 PROPRIETARY INFORMATION
Work Process Optimization • Primary Steps
−As-is Process Mapping −To-be Process Mapping (Optimization) − Implementation
• Typical Process Engineering Work Processes −Process Simulations – Development, Usage,
Maintenance −Linear Program – Updating and Backcasting −Optimization – Idea Generation through Implementation
17 July 2012 21 PROPRIETARY INFORMATION
Progression Path • Technical Career Progression
−Align rotations with organization and individual needs
• Development and Training −Situational Training −Lessons-Learnt
Training −Case Study based
exercises −Coaching and
Mentoring −Self-paced Learning −Communities of
Practice 17 July 2012 22 PROPRIETARY INFORMATION
Final Steps and Lessons • Roll-out, Maintenance, and Continuous
Improvement • Pitfalls and Lessons Learned
−Avoid skipping steps −Do not just make the effort a staffing numbers activity −One size does not fit all − Include a broad experience base in all phases −Think through the entire process and all phases −Over-communicate throughout the process − Identify and pursue “quick-wins” early on to help build
on success 17 July 2012 23 PROPRIETARY INFORMATION
Summary • Demographic Shifts
Impacting Energy Industry • Organizations need to drive
Process Engineering skill development and knowledge retention
• Process Engineering Best Practice Standard can facilitate achieving improved human performance
17 July 2012 24 PROPRIETARY INFORMATION
Closing > For information on how KBC can help you with
developing your engineering staff, please contact us at [email protected]
> Future webinar topics: – Market conditions – Asset optimisation for competitive advantage – Investment support – Sustainable workforce development
> We welcome suggestions for future topics – please email [email protected]
> Next webinar information will go out shortly. > Thank you for joining us!
17 July 2012 PROPRIETARY INFORMATION 25
