Systems and Work Processes: The need of Integration, to achieve - - PowerPoint PPT Presentation

Systems and Work Processes: The need of Integration,

to achieve Operational Excellence

SHASHWAT ANAND

RELIABILITY ENGINEER EQUATE PETROCHEMICAL COMPANY

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WELCOME

to one of the best Petrochemical plants in the World

www.equate.com

EQUATE Petrochemical Company

About EQUATE

Established in 1995, EQUATE Petrochemical is Kuwait’s first-ever international petrochemical joint venture, and is the single operator of a fully integrated world-scale Kuwait-based manufacturing facility that annually produces over 5 million tons of high quality petrochemical products.

OUR VISION WE ARE A GLOBAL LEADER & WORLD CLASS PRODUCER OF PETROCHEMICALS

OUR MISSION

WE PROVIDE VALUED PRODUCTS & SERVICES TO THE WORLD

OUR VALUES

• Customer Centricity
• Safety & Reliability
• Teamwork & Partnership
• Sustainability
• Continuous Improvement & Progression

EQUATE at a glance

PROVIDING VALUED PRODUCTS TO THE WORLD

PROFIT PRODUCTS EMPLOYEES OFFICES AWARDS

US$ 1.1 Billion (2012) PE / EG / SM PX / BZ / HA / PP 1400 Employees 4 Offices Globally National & International Awards

The Greater EQUATE JV

G L O B A L E X P A N S I O N T O M E E T I N C R E A S I N G W O R L D W I D E D E M A N D F O R F I R S T - R A T E P E T R O C H E M I C A L P R O D U C T S , E Q U A T E ’ S S H A R E H O L D E R S A N D K U W A I T N A T I O N A L P E T R O L E U M C O M P A N Y ( K N P C ) C O M P L E T E D A M U L T I - B I L L I O N D O L L A R E X P A N S I O N P R O J E C T I N 2 0 0 9 W H I C H G R E A T L Y I N C R E A S E D O U T P U T .

Ethylene Glycol Capacity: 600,000MT Styrene Monomer Capacity: 450,000MT Paraxylene Capacity: 829,000MT Polypropelene Capacity: 140,000MT

Company Shareholders Product Capacity Market Outlet

EQUATE PIC 42.5% Dow 42.5% BPC 9% QPIC 6% PE EG 825,000 550,000 EMC MEGlobal TKOC PIC 42.5% Dow 42.5% BPC 9% QPIC 6% EG 600,000 MEGlobal TKSC KARO 57.5% Dow 42.5% SM 450,000 EMC KPPC KARO 100% PX HA BZ 829,000 80,000 393,000 PIC PIC Not for commercial sales. Used

• nly for SM production.

PIC PP Plant (Operated by EQUATE) PIC 100% PP 140,000 PIC KARO PP Plant (Operated by EQUATE) PIC 40% KNPC 40% QPIC 20% All production of KARO is done by KPPC.

EQUATE as Single Operator

• All capacities are metric tons annually.
• Ethylene is only used as feedstock, not for sale.
• KARO: Kuwait Aromatics Company.

Corporate Strategy

OUR PRODUCTS

AS THE PROUD OWNER AND OPERATOR OF SEVERAL WORLD- CLASS PETROCHEMICAL UNITS, EQUATE MANAGES THE PRODUCTION OF THE HIGHEST GRADES OF;

Ethylene, Polyethylene (PE), Ethylene Glycol (EG), Polypropylene (PP), Styrene Monomer (SM), Paraxylene (PX), Heavy Aromatics (HA) and Benzene (BZ).

• Unipol Polyethylene Process
• Leading Glycol Technology
• Global Marketing Expertise
• Utility Infrastructure
• Dedicated Port

Facilities

• Overall Infrastructure
• Supply of Ethane
• Plant Infrastructure
• Skilled Personnel

Private Sectors to Promote downstream industries

Providing value through Partnership

OUR AWARDS & ACCREDITATION

Introduction

Manufacturing industry has identified the importance of transparent information ecosystem that effectively leverages data and information. Management understands the need to have timely access to key information in order to minimize risks around reliability and availability to ensure effective decision-making. While developing the various systems and work processes, the industry is now realizing an exponentially increasing amount of data; silo’d in various systems and work processes. From “No system”, we are moving towards “Too many Systems”.

Various systems in Manufacturing industry

Computerized Maintenance Management System (CMMS) Management of Change (MOC) Document Management System (DMS) Root Cause Analysis system RCM/ FMEA Inspection Management System (IMS) Historian System Alarm Management system Spare Optimization System And many…..

Standalone system Vs Integrated system

Standalone system

Characteristics:

Silo’d information Repetition of data entry More chances of human error Individual system report generation Integrated System

Characteristics:

Interconnected information Lower amount of data entry Less chances of human error Centralized report generation

Introduction of new system: Challenges

Factors affecting the acceptance of new system / work process among the employees I. Value perception seen by the employees

• II. Work simplicity (Perception)
• III. Additional workload
• IV. Repetition of job

How an integrated system can help in creating more value

I. Use of existing information hence low effort in data entry II. Low /minimum chances of human error

• III. Avoidance from data entry repetition
• IV. Effortless and errorless report generation if the same is planned

and implemented properly

• V. Easy to understand with the experience of existing system

• VI. Encouraged participation of employees in implementation of new

system to address a current challenge with existing system

• VII. Improvement in quality of data

VIII.Value for stakeholders

• IX. Time saving/ Productivity improvement

X. Easy access to information

Benefits…

Roadmap to a successful implementation

• f a new system/ work process

Welcome the Idea Initial screening Make or Buy decision Educate about the IT capabilities

• Associate IT expert, if

required

Roadmap to a successful implementation of a new system/ work process

Continued…

Brain storming in all possible directions

• Integration of information with

existing systems

• Don't rule out the possibility of

discarding an existing system

Define KPIs

• Report may include

KPIs from existing systems

Emphasize on Automated report

Role of Management / Leaders

• 1. Mentorship in enlightening the team with the set of questions to

be asked at the time of initial screening

• 2. Enable the team to identify the third party software already in

practice

• 3. Enable the team to recognize the IT capabilities
• 4. Support for integration with other existing systems and work

processes

• 5. Support for defining the KPIs and automated reporting system

Recommended Questions during the brainstorming

• 1. Is the new system really required
• 2. How is it going to create value for the stakeholders
• 3. In-house

development

• f

the new system/ work process

• r

implementation of a third party software. i.e. Make or Buy decision

• 4. Can we customize the third party software to create more value

for stakeholders

• 5. What information can be used from the existing systems/ work-

processes

• 6. Which data need to be entered in the new system

Recommended Questions during the brainstorming

• 7. Can we import some data from the existing system
• 8. Can we export some data to the existing system
• 9. Can we discard an existing system by revising the current requirement
• f the new system
• 10. Which KPIs we are looking for (from the new system)
• 11. Can we automate the report generation from the new system
• 12. Can we merge other KPIs/ Reports from the other existing systems/

work processes.

Goal

Integrated system with smooth Implementation

Step Forward

Oil & gas field is more prone to risks and uncertainty. Also, to cope up with the rising competition and strict environmental challenges in Oil & Gas field, “Expected reaction time” is less. With the advancement in IT field, it is now time to move forward to Real time reporting systems Real time reporting systems definitely are the demand of the current time to achieve Operational Excellence.

Automated Consolidated Report / Real-Time Dashboard

Computerized Maintenance Management System (CMMS) Inspection Management System (IMS) Historian System Production Planning Financial Management System Marketing Management System

Long Term Goal

Thanks

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