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Hasler Process Performance Engineer at Holcim

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728 views

Hasler Process Performance Engineer at Holcim

Uploaded by

vikubhardwaj9224
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
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Technical Development Program for

Process Performance Engineers

The Process Performance


Engineer at Holcim
René Hasler HGRS/MS-TPT
Holcim considers the process engineer function as a
key to achieve excellence in manufacturing performance

Frequent Situation
- Function existed in most plants in the past, but has disap-
peared in many plants
- Where it exists, it is often not given the right tasks, respon-
sibility and authority
- Therefore, this function is unfortunately frequently considered
as short term job to move into another position

Objective
- Every plant has a Process Performance Engineer function with
clearly defined roles and responsibilities

2
© Holcim Group Support Ltd 2008 Technical Development Program for PPE 07.11.2008/Hs
Group Operational Roadmap 2006-2010
2006 2007 2008 2009 2010
Financial   HVA 500 mio  Op. EBITDA margin CEM > 33%
 Op. EBITDA margin AGG > 27%
 Op. EBITDA margin OCM > 8%

BCM  PMP implemented  Cost target per plant


 achieved
Net Availability:  90% / Net OEE:  85%
 Aggregates reserves management system implemented
 IT Cost: < 1.5% Net Sales  ITSCs ISO 20000 & 27001/2 implemented
 1.5% (2006) / 2% p.a. (2007-08) Procurement Benefits on Non-Capex

PMI  spend
PPM for cement completed  PPM cement review completed
 Brand "looks like" compliant  Brand values embedded
 HVC defined  Best Premium Brand perception achieved
HRE  Succession management (level 1-3)
Action and development plans implemented

SEP  Group emission data & ERT public*  GAV target 350 mio  Group ERT –20% dust,
 Group CO2 target achieved* NOX and SO2 achieved*

CSR  Green OH&S Pyramid achieved


 LTIFR of 2004 reduced by  30% p.a. (2006-09) until < 2

* In line with WBCSD commitments of Holcim Group 3


© Holcim Group Support Ltd 2008 Technical Development Program for PPE 07.11.2008/Hs
Holcim‘s Manufacturing Goal is to achieve
excellence in cement manufacturing performance
 Zero accident
 High clinker quality and low clinker factor
 Uniform cement quality at specified quality level
 Compliance with emission rules and limits
 Optimized operating assets
- OEEnet = 85%
- net Availability = 90%
 Maximum use of AFR and petcoke
 Minimum specific thermal and electrical energy consumption
 Low production cost

The Process Performance Engineer supports and enables


the achievement of these goals !
4
© Holcim Group Support Ltd 2008 Technical Development Program for PPE 07.11.2008/Hs
Specific Tasks of the Process Performance Engineer
 Continuously monitor and analyze process, equipment performance
 Implement Holcim standard measurements, tools and procedures
 Carry out benchmarking and support implementation of conclusions
 Ensure use of expert process control systems (LINKman)
 Take initiative and propose solutions for improvements conside-ring
use of new technologies and equipment
 Promote and support optimal use of AFRs and petcoke with impact
studies on process, clinker quality and emissions
 Implement standards for sustainable environmental performance and
for safety of the plant’s processes
 Provide process know-how to the plant’s CAPEX-projects
 Train and coach operation personnel in process knowledge and in
application of standard operating procedures and targets
 Look for and implement useful practices (ICM, CoPs, literature, etc.)
and contribute to knowledge sharing in Holcim Group
5
© Holcim Group Support Ltd 2008 Technical Development Program for PPE 07.11.2008/Hs
The Process Performance Engineer function is a very
demanding position, requiring…

 Highly qualified engineer with


- technical competence, i.e. excellent knowledge of cement
manufacturing processes in theory and practice, combined with
industrial experience
- capability of systematic problem analysis and solving
- social skills to act as team player
- focus on performance and results

 Clear definition of tasks and responsibilities


- Adequate positioning in plant organization
- High level of acceptance by the plant team

6
© Holcim Group Support Ltd 2008 Technical Development Program for PPE 07.11.2008/Hs
Group’s manufacturing support architecture. Specific responsibilities at
three levels: Corporate, Regional and Plants.
Specific responsibilities
Main highlights: Manufacturing policies and knowledge management
 Global benchmarking, target setting
Group  Defining manufacturing policies and standards
EXCO  Defining and implementing global improvement programs
 Operational activities requiring high level expertise
 Monitoring and challenging performance
 Developing experts and professionals
 Leading Technological development and applied research
Regions1) HGRS/MS  Safeguarding and protecting critical know how

Region1) Main highlights: Support and challenge


 Specific benchmarking and target setting
Regional Mgt  Implementing Group policies and standards
 Supporting implementation of improvement programs
 Developing specific manufacturing plans
 Operational activities requiring experts and professionals
 Monitoring and challenging plants performance
Plants RMSO2)  Coaching plant professionals

Plant Main highlight: Perform


Plant Mgt  Implementing global programs and specific plans
 Performing plant operational activities
 Monitoring plant performance
 Build up and maintain first level expertise
 Training plant personnel
Plant Dpts. Plant Support

Decision makers Support & challenge Manage and operate


A region is defined as an operational unit with several plants (Group company, functional cluster, European regions or trans-borders group
1)

of companies/plants) 2)
Regional Manufacturing Support Organization
7
© Holcim Group Support Ltd 2008 Technical Development Program for PPE 07.11.2008/Hs
Holcim’s Technical Committee advises that …

 Every plant shall have the process performance engineer’s function,


with clearly defined role

 HGRS to organize and carry out a development program for Process


Performance Engineers with Holcim certification

 Positioning and integration is decided by individual companies

8
© Holcim Group Support Ltd 2008 Technical Development Program for PPE 07.11.2008/Hs
Position of Process and Performance Engineer
Plant Plant
Manager Manager

Production Production Process


Manager Manager Engineer

Process
Engineer

Production Production
Personnel Personnel

9
© Holcim Group Support Ltd 2008 Technical Development Program for PPE 07.11.2008/Hs
Message

The Process Performance Engineer


is a most important function in
each Holcim plant!

10
© Holcim Group Support Ltd 2008 Technical Development Program for PPE 07.11.2008/Hs

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