Slide 1Pursuing our vision:Slide 3Serving customers’ diverse needs…Dow Corning innovating around the worldThe Charge of Automation and Why Dow Corning Pursues it!Spirit of S88S-88 Expectations212 Building (Cell) Pulp/Paper CoatingsOEE – Overall Equipment EffectivenessOperator Graphics – Building Level (Cell)Operator Graphics - EMsSlide 13Slide 14Slide 15A Simplier BreakdownSlide 17Slide 18How did we get there?But I could do all that without S-88!Typical Dow Corning BenefitsWyeth-Ayerst Lederle Recipe Case StudyWyeth-Ayerst Lederle Case Study, Cont.Wyeth-Ayerst Lederle Case Study, Cont.Recipe CreationS-88 Limitations and Realistic ExpectationsSlide 27Slide 28207 Building (Cell) Silicone Rubber ProductionInnovation is at the core of what we doGrowing globally & S-88 is used throughoutSlide 32Slide 481Dow Corning Corporationdowcorning.comDow Corning Corporationdowcorning.comRussell CzolgoszJanuary 22nd, 2010Russell CzolgoszJanuary 22nd, 201022Pursuing our vision: We are innovative leadersunleashing the power of siliconto benefit everyone, everywhere.Living our values: Integrity Employees Customers QualityTechnology SustainabilitySafety33Dow Corning locations worldwideManufacturing Sites44Serving customers’ diverse needs…55Dow Corning innovating around the worldMore than 7,000 products and related services Approximately 25,000 customersOver $5 billion in sales in 2008, globally dispersed with more than 60% outside the USApprox. 10,000 employees worldwideA global leader in silicones and high purity siliconStrong channels to market – distributors, web, commercial organizationThe Charge of Automationand Why Dow Corning Pursues it!Implement and support automation solutions, position strategic automation capabilities that ensure safety and security which generate savings of $100M - $150M over a five year period and sustain manufacturing operability by using best practices, standardized technologies, and leveraging existing expertise to accelerate manufacturing productivity.Spirit of S88•S88 isn’t just a standard for software, equipment, or proceedures•It’s a way of thinking, a design philosophy•Understanding S88 will help you better design your processes and manufacture your productsS88 works with ALL levelsof automationS-88 Expectations•Decreased Batch Cycle Times•Increased Cell Productivity•Reduced Product to Market Commercialization Time–IE, New Recipe Creation•Configurable/Changeable Recipes•Consistent Product Quality•Standardized Vocabulary•New ways to SPC the process–Duration of Operations and phases8212 Building (Cell)Pulp/Paper Coatings•5 types of Units - –Equilibration Kettles–Feed Tank–Volatiles Stripping•60 recipes•Average Batch Time ~ 20 Hours•More than 2,100 batches / year / cell@ 90% OEEOEE – Overall Equipment Effectiveness•Availability = Operating Time / Planned Production Time•Performance = (Parts Produced * Ideal Cycle Time) / Available TimeIdeal Cycle Time is the minimum cycle time that your process can be expected to achieve in optimal circumstances. It is sometimes called Design Cycle Time, Theoretical Cycle Time or Nameplate Capacity.•Quality = Good Pieces / Total Pieces•OEE = Availability x Performance x Quality•OEE Factors in downtime (scheduled and unscheduled), bad quality, and of not running at design rates10Operator Graphics – Building Level (Cell)Operator Graphics - EMsBase GraphicEquipment Module GraphicDischarge Phases:•Discharge Shutdown (all stop)•Discharge Back to Kettle (Recycle)•Discharge through Filter•Discharge through Heat Exchanger 1•Discharge through Heat Exchanger 2•Discharge through Heat Exchanger 1 & 2•Discharge through Heat Exchanger 2 and FilterRecipe StructureA Simplier Breakdown•Original Code was 186 sequential steps, with 6 actions per step•New Code is 9 Equipment modules and 39 total phases–Jacket Temperature–Agitation–External Heat Exchanger–Vessel Pressure Blanketing / Vacuum–Raw Material Feeds–Catalyst Feeds–Atmosphere Inerting–Bottoms Liquid Recirculation / Filtration–Timing and MessagingDischarge Phases (7):•Discharge Shutdown (all stop)•Discharge Back to Kettle (Recycle)•Discharge through Filter•Discharge through Heat Exchanger 1•Discharge through Heat Exchanger 2•Discharge through Heat Exchanger 1 & 2•Discharge through Heat Exchanger 2 and Filter1703-Sep-02 11:33:4606-Apr-03 18:05:1613-Sep-03 07:50:1610-Dec-03 01:37:4620-Feb-04 10:47:0101-Jun-04 21:18:0125-Aug-04 18:24:1606-Nov-04 16:16:0101-Feb-05 05:38:0117-Apr-05 22:46:0105-Jul-05 17:19:3102-Sep-05 07:20:1624-Oct-05 09:14:4612-Dec-05 06:42:4609-Mar-06 02:42:1606-Jun-06 06:27:4627-Aug-06 18:18:1630-Nov-06 10:16:0122-Apr-07 19:36:4620-Oct-07 16:26:4601-Dec-07 18:21:0106-Jan-08 06:33:2115-Feb-08 04:50:2521-Mar-08 06:42:1521-Apr-08 13:58:3528-May-08 10:48:5906-Jul-08 15:09:2022-Aug-08 13:52:0715-Nov-08 07:22:4724-Mar-09 03:47:0916-May-09 16:15:4928-Jun-09 20:56:2621-Aug-09 06:59:3731-Oct-09 05:26:0418-Dec-09 13:55:540.010.020.030.040.050.060.070.0Example Kettle Batch TimesHours1803-Sep-02 11:33:4606-Apr-03 18:05:1613-Sep-03 07:50:1610-Dec-03 01:37:4620-Feb-04 10:47:0101-Jun-04 21:18:0125-Aug-04 18:24:1606-Nov-04 16:16:0101-Feb-05 05:38:0117-Apr-05 22:46:0105-Jul-05 17:19:3102-Sep-05 07:20:1624-Oct-05 09:14:4612-Dec-05 06:42:4609-Mar-06 02:42:1606-Jun-06 06:27:4627-Aug-06 18:18:1630-Nov-06 10:16:0122-Apr-07 19:36:4620-Oct-07 16:26:4601-Dec-07 18:21:0106-Jan-08 06:33:2115-Feb-08 04:50:2521-Mar-08 06:42:1521-Apr-08 13:58:3528-May-08 10:48:5906-Jul-08 15:09:2022-Aug-08 13:52:0715-Nov-08 07:22:4724-Mar-09 03:47:0916-May-09 16:15:4928-Jun-09 20:56:2621-Aug-09 06:59:3731-Oct-09 05:26:0418-Dec-09 13:55:540.010.020.030.040.050.060.070.0Example Kettle Batch TimesHours31.3 Hours24.5 Hours62.8 UCL37.4 UCLHow did we get there?•Okay, so 22% reduction in average batch cycle time! Wow!–2 ingredients were loaded in series2 ingredients are loaded in parallel–Agitation was started after both raw materials were loadedAgitation starts as soon the bottom impeller is submerged–Mix time used to be 1 hour to ensure adequate mixingMix time was left at 1 hour…but ingredients are loaded at a constant ratio to each other–Heating began only when all ingredients were loaded and mix time completedHeating begins just after kettle loading is 1/10 complete19But I could do all that without S-88!•Yes, you could, if you knew it all in the beginningand, if