Slide Number 1CM4120 Chemical Plant Operations Lab Introduction to Chemical ManufacturingCM4120 Chemical Plant Operations Lab Introduction to Chemical ManufacturingSlide Number 4Slide Number 5Slide Number 6Slide Number 7Slide Number 8Slide Number 9Slide Number 10Slide Number 11Slide Number 12Slide Number 13Slide Number 14CM4120 Chemical Plant Operations Lab Quality ManagementCM4120 Chemical Plant Operations Lab Quality ManagementCM4120 Chemical Plant Operations Lab Quality ManagementCM4120 Chemical Plant Operations Lab Quality ManagementCM4120 Chemical Plant Operations Lab Quality ManagementCM4120 Chemical Plant Operations Lab Quality ManagementCM4120 Chemical Plant Operations Lab Quality ManagementCM4120 Chemical Plant Operations Lab Quality ManagementCM4120 Chemical Plant Operations Lab Quality ManagementCM4120 Chemical Plant Operations Lab Quality ManagementCM4120 Chemical Plant Operations Lab Quality ManagementSlide Number 26CM4120 Chemical Plant Operations Lab Introduction to Supply Chain ManagementCM4120 Chemical Plant Operations Lab Introduction to Supply Chain ManagementCM4120 Chemical Plant Operations Lab Introduction to Supply Chain ManagementCM4120 Chemical Plant Operations Lab Introduction to Supply Chain ManagementCM4120 Chemical Plant Operations Lab Introduction to Supply Chain ManagementCM4120 Chemical Plant Operations Lab Introduction to Supply Chain ManagementCM4120 Chemical Plant Operations Lab Introduction to Supply Chain ManagementCM4120 Chemical Plant Operations Lab Introduction to Supply Chain ManagementCM4120 Chemical Plant Operations Lab Introduction to Supply Chain ManagementCM4120 Chemical Plant Operations Lab Introduction to Supply Chain ManagementCM4120 Chemical Plant Operations Lab Introduction to Supply Chain ManagementIntroduction to Chemical ManufacturingCM4120Chemical Plant OperationsD. CasparyJanuary, 20101CM4120Chemical Plant Operations LabIntroduction to Chemical ManufacturingOutline:y Chemical Engineering’s Role in Industryy Internal and External Influences and Constraintsy What is meant by Quality Management?y What is meant by Supply Chain Management?2CM4120Chemical Plant Operations LabIntroduction to Chemical ManufacturingPrimary Goal of Chemical Manufacturing?How does your company achieve that goal?3• Agricultural Products• Automotive• Coatings and Adhesives• Consumer Products• Energy• Environmental Remediation• Food Processing• Intermediate Products• Petrochemical• Pharmaceutical / Health Care• Polymer Processing• Pulp and Paper• Semiconductor Industry4Broad Range of Industries:CM4120Chemical Plant Operations LabIntroduction to Chemical ManufacturingEntry-level titles for B.S. Chemical Engineers:• Chemical Engineer• Process Engineer• Product Specialist• Product Engineer• Project Engineer• Research Engineer• Production Engineer5CM4120Chemical Plant Operations LabIntroduction to Chemical ManufacturingJob Responsibilities will include:• Provide service or product on a timely basis• Manage supplier relationships• Manage customer relationships• Expand existing markets• Develop new products• Continuing education/professional development6CM4120Chemical Plant Operations LabIntroduction to Chemical ManufacturingKey events of the past 10 to 15 years have changed the business climate…7CM4120Chemical Plant Operations LabIntroduction to Chemical Manufacturing• Breakup of Soviet Union• Free/open trade between Western European countries – EU and Euro• NAFTA and CAFTA, future FTA’s• China granted Most-Favored-Nation trading status• Adoption of Shipping Containers• Expanding markets, manufacturing/ infrastructure development in India, China, Pacific Rim, and African nationsCatastrophes (man-made & natural) impact the manufacturing environment…• 9/11 Incident and other terror attacks worldwide• Major weather events• War and civil unrest• Instability in the price of oil• Stock market crash and lending crisis of 2008• “Reinvestment” programs and changes to tax codeCompanies must adapt to survive8CM4120Chemical Plant Operations LabIntroduction to Chemical ManufacturingBusiness ConstraintsYour company must maintain a level of competitiveness/profitability while complying with:• Environmental, Health, and Safety regulations• Labor laws• Tax laws• Patent Law• Homeland Security Act• International trade agreements9CM4120Chemical Plant Operations LabIntroduction to Chemical ManufacturingAdditional Constraints:• Certifications, validation, or quality assurance standards• Supplier and customer audits• Internal politics/ biases• Your own moral and ethical standardsNeed to critically review all aspects of the business and yourself to maintain competitive edge.10CM4120Chemical Plant Operations LabIntroduction to Chemical Manufacturing11Ways to improve/ maintain profitability:Increase Income increase throughput increase on-time order fulfillment improve stability of process improve quality increase equipment utilization new productsDecrease Expenses reduce inventory – product, feedstocks, spares maintenance costs labor costs production costs environmental releases energy costs off-spec productCM4120Chemical Plant Operations LabIntroduction to Chemical ManufacturingAll improvements fall into one of two categories:Improved processing and control thru Quality Management, orIncreased profitability thru efficient Supply Chain Management12CM4120Chemical Plant Operations LabIntroduction to Chemical ManufacturingYour company is driven to continuous improvement• by your customers• by your competitors• by a changing world13In summary:What you (your company) did yesterday isn’t good enough for tomorrow!CM4120Chemical Plant Operations LabIntroduction to Chemical Manufacturing14Increased Profitability thruQuality ManagementCM4120Chemical Plant Operations LabQuality ManagementHow is Quality defined?Quality is what adds value to your raw materials.ISO9000: The totality of features and characteristics of a product or service that bear on its ability to satisfy stated or implied need.Quality is always defined by the customer.15What is Quality Management ?Managing systems and processes for the elimination of errors.Creating an environment for continuous improvement.16CM4120Chemical Plant Operations LabQuality ManagementFormula for a generic process:A+B=Cwhere A=system contribution,B=human contribution, andC=desired (measurable)