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AVisionfortheFutureofProcessAnalysisandControlinManufacturingPresentationtoCPACTConferenceAdvancesinProcessAnalysisandControlTuesday,3April2001ProfessorRogerBensonFREng+(44)1642372379
ABBEutechisasuccessfulbusinessTrackrecordofprofitablegrowthRobust&sustainable-irrespectiveofownershipDiversifiedclientportfolio-150customersworld-wideUniqueportfolioofservicesandexperience
IntegratedoffertothemanufacturingandprocessingindustriescombiningConsultancyProfessionalengineeringservicesManufacturingexperience/operationalheritageFocusonbenefits/value-performanceimprovementIntroductiontoABBEutechWithawideClientPortfolioPharmaceuticalsAstraZenecaGlaxoWellcomePfizerSKBNovartisHeavyChemicalsBPChemicalsDuPontEVCBASFUnionCarbideFMCG/FoodandDrinkGlobalconfectionery/grocerymanufacturersSKChilledFoodsUnitedDistillersAlliedDistillersEdenvaleSpecialityandFineChemicalsRohmandHaasHicksonandWelchCibaSpecialityChemicalsICILearningfromHistory
Pressureonunitcostse.gParametricreleaseofdrugsandotherregulatedproductsIncreasingcompetitione.gRestructuringIncreasedcapitalproductivitye.gFocusonworldclassmanufacturingMoredemandingcustomerse.g6SigmaIncreasinglegislativeandregulatorypressurese.gzeroSHEincidentsNeedtodelivershareholdervaluee.gfasterinnovationChangingMarketplaceLearningfromcars-outsourcePRIMEINDUSTRY1st
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SUPPLIERSCapabilitiesThepropositionTheBenefitsAssetManagementandOperationsImprovementDeliverscapitalproductivityImprovesmanufacturingperformanceAssuresLicencetooperateExtendsassetlifeLicencetooperateOperationsimprovementOperationalsupportGrowthandinvestmentProcessenhancementKnowledgemanagementPeopledevelopmentFunctionalExcellenceABBEutech’sresponse
AssetManagement&OperationsImprovement
WhatcouldthismeanforCPACT?Industrieswhichhavetheneedandthemoneybutlimitedresourcestotranslate,developorsupportFirsttiersuppliersdevelopandexploittheresearchAssistancewithinterpretationandexploitationofthebenefitsRequirementforremotesupportandcalibrationoverthewebCPACTmayhavetoexploitandsupportitsownresearchThreatstodayLicensetooperate
LegacyissuesLitigationZeroSHEissuesGreenpeaceissues/SustainabilityGlobalmarket,globalinformationdrivingdownpricesInternetreducesabilityofpoliticianstoregulateandallowsfrictionlesscapitalismReducedinnovationcycletimeWhatcouldthismeanforCPACT?MeasurementandreportingonpollutantsoverthetotallifecycleMovefurtherdowntheInnovationcycleKnowhowbecomestheprotection-hencereluctancetopublishResearchmustconsidertheimpactontheInternetasatopicinitsownrightandhowfuturesupportisprovided.CPACTmayhavetocreateabusinessImpactofthesupplychainCustomerServiceBusinessprocessesSupplierperformanceAsseteffectivenessFinishedGoodsStockTurnCustomercomplaintsCustomerOTIFLead-timeSupplychaincostsForecastaccuracyNewproductintroductiontimeActivitybasedcostingallocationCashtocashcycletimeSupplierOTIFRawmaterialstockturnSupplierCpkSupplierlead-timeProcesscapability(Cpk)OEE(continuous/batch)ValueaddedproductivityGradechangetimesSafetyAframeworktomeasuring&benchmark
SupplyChainperformanceSomeBenchmarksStock-asymptomofinabilitytocontrolUncoveringtheRocksABBProductQualityPlantLayoutProcessCapabilityTermsofPaymentSalesPromotionsLongChangeoversSuppliersReliabilityUncertainDemandHIGHINVENTORIESPOORMARKETRESPONSEEXCESSCOSTSSomeBenchmarkssPPMWhat“Sigma”means...23456308,53766,8076,2102333.4IncreasingProcessCapability(Cpk)DecreasingCostofPoorQualityControltheProcessxxxLSLUSLTheProcessLSLUSLLCLMEANUCLLCLMEANUCLLCLMEANUCLLCLMEANUCLWhatcouldthismeanforCPACT?On-linemeasurementanddisplayofallthesupplychainperformancemeasuresinthecontrolroom
AdynamicmultivariatetaskSomeofthemeasurementssourcesareinthefinancialreportingstructure,withcustomersandsuppliersCommerciallysensitivemeasurement.CPACTpurposeIndustrialinformationtechnologyIntegrateon-linemeasurementwithintelligencetoclosetheBusinessloop
IfyouareunabletomeasureyouareunabletoclosethebusinessloopTheveryreasonCPACTwascreatedWhatareweunabletomeasure?On-lineComplexchemicalmixturese.gOrganicresiduesRateofreaction/chemicalreactionsPowdermixingFinalcustomerpropertiese.gTaste,smellBiochemicalmolecules/fermentationprocessesPrecipitation/crystallisationRateofbuildupofdepositsWhatareweunabletomeasure?Offandon-lineinrealtime SomekeymanufacturingandsupplychainmeasuresInvisiblebar-codesDynamicmultivariateperformancemonitoringSupportingtoolsandtechniquesSupport&re-calibrationoverthewebInterfacebetweentheanalysisandthebusinessmodelAndtechnologykeepsarrivingCheapimagingAcousticsSolidstateNIR,UV,NMR,Ramanetc.MicrowavespectroscopyLabonamicro-chipEverfastercomputerswithevenmorememoryChemeometricsonachipDoesitmatter?
PotentialshorttermimpactsExistingmanufacturingplants
Upto30%extraoutputDoubleassetturnbydesigningformanufacturingHalfOPEXdeliverytime
6Sigmaquality
FocusonNPDprocesses
Release5%ofsalesturnoverfromsupplychainimprovement
Allatafasterratethanthemarketsaregrowing!
Acquisitions,synergisticsavings,removingHQcostsWinnersgrow,losersdisappearTomorrow’sopportunities?Tomorrow’sopportunitiesWorldClass……….’TheJourney’……….TomorrowGainingControlProactiveDistributed
CustomizeManufactureAgileRadicalimprovementExcellentmanufacturingvelocityetcSupplychainisvalueaddingOutstandingcustomerservicewithzerostockContinuousimprovementExcellentOEEetc.ManufacturingisvalueaddingFocusuponcustomersVirtuousReactiveFirefightingPoorperformance,SHE,OEE,etc.ManufacturingisacosttothebusinessInternalconflictWorldClassTraditional-CustomizeAgile-SupplyChainStepchangesinprocesstechnologyGainingControlStrategyandPeopleCapabilityImprovetheCorePracticesMeasureandActManufacturing2020ManufacturingtoaunitofoneDistributedmanufacture,designforAgility,linkcustomer<->manufacturer
Valuechainco-managementAMOIpropositions,sharedtechnologydevelopment
Anenvironm
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