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

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. EQUATE Petrochemical Company www. equate .com

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

OUR MISSION WE PROVIDE VALUED PRODUCTS & SERVICES TO THE WORLD

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

EQUATE at a glance PROFIT PRODUCTS EMPLOYEES OFFICES AWARDS National & US$ 1.1 PE / EG / SM 1400 4 Offices International Billion (2012) PX / BZ / HA / PP Employees Globally Awards PROVIDING VALUED PRODUCTS TO THE WORLD

The Greater EQUATE as Single Operator EQUATE JV Company Shareholders Product Capacity Market Outlet PIC 42.5% PE 825,000 EMC Dow 42.5% EQUATE BPC 9% EG 550,000 MEGlobal QPIC 6% G L O B A L E X P A N S I O N PIC 42.5% Dow 42.5% T O M E E T I N C R E A S I N G EG 600,000 MEGlobal TKOC W O R L D W I D E D E M A N D F O R BPC 9% F I R S T - R A T E P E T R O C H E M I C A L QPIC 6% 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 KARO 57.5% C O M P A N Y ( K N P C ) C O M P L E T E D SM 450,000 EMC TKSC A M U L T I - B I L L I O N D O L L A R Dow 42.5% 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 . PX 829,000 PIC KARO 100% HA 80,000 PIC KPPC BZ 393,000 Not for commercial sales. Used only for SM production. PIC PP Plant PIC 100% PP 140,000 PIC (Operated by EQUATE) PIC 40% KARO PP Plant KNPC 40% All production of KARO is done by KPPC. (Operated by EQUATE) QPIC 20% • All capacities are metric tons annually. • Ethylene is only used as feedstock, not for sale. • KARO: Kuwait Aromatics Company. Ethylene Glycol Styrene Monomer Paraxylene Polypropelene Capacity : 600,000MT Capacity : 450,000MT Capacity : 829,000MT Capacity : 140,000MT

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).

Providing value through Partnership Private Sectors to Promote downstream industries • Utility Infrastructure • Dedicated Port Facilities • Overall Infrastructure • Unipol Polyethylene Process • Leading Glycol Technology • Global Marketing Expertise • Supply of Ethane • Plant Infrastructure • Skilled Personnel

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

Standalone system Vs Integrated system Standalone system Integrated System Characteristics: Characteristics: Silo’d information Interconnected information Repetition of data entry Lower amount of data entry More chances of human error Less chances of human error Individual system report generation 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

Benefits… 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

Roadmap to a successful implementation of a new system/ work process Welcome the Idea Initial screening Make or Buy decision Educate • Associate IT expert, if about the IT required capabilities

Roadmap to a successful implementation of a new system/ work process Continued… • Integration of information with Brain storming existing systems in all possible • Don't rule out the possibility of directions discarding an existing system • Report may include Define KPIs 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 of the new system/ work process or 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 of 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.

Long Term Goal Computerized Maintenance Management System (CMMS) Marketing Inspection Management Management System System (IMS) Automated Consolidated Report / Real-Time Dashboard Financial Historian Management System System Production Planning

Thanks

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