Interview

Bayer Material Science AG

Dr. Johannes Eickmanns
Department Head Change Management Production and
Technology

...
Interview Partner: Peter Haack and Dr.
Johannes Eickmans.
After studying physics Dr. J. Eickmans worked
as a post-doc for ...
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Interview with Dr. Johannes Eickmanns, Bayer Material Science AG / Germany

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Prior to the Global ManuChem Strategies 2014, we spoke to Dr. Johannes Eickmans, Department Head Change Management Production and Technology, Bayer Material Science AG / Germany

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Interview with Dr. Johannes Eickmanns, Bayer Material Science AG / Germany

  1. 1. Interview Bayer Material Science AG Dr. Johannes Eickmanns Department Head Change Management Production and Technology Prior to the Global ManuChem Strategies 2014, we spoke to Dr. Johannes Eickmans, Department Head Change Management Production and Technology, Bayer Material Science AG / Germany we.CONECT: In your opinion: What are the main current challenges and trends regarding management and optimization of chemical production and what are the specific challenges related to your company? Dr. Johannes Eickmans: There are no new challenges in general, apart from one exception: the stronger focus on energy management. Additional challenges are the cost of raw materials, the European legislation and the public perception of the risk and benefits of chemical production. At BMS we have challenges in optimizing our turnaround management: We are extending the cycle to 4 - 5 years (2% turnaround losses p.a.). And of course we have to make sure that the plant runs reliably in the meantime. we.CONECT: Looking to volatility in commodity markets, which role plays operations management, specifically S&OP and plant capacity management? Dr. Johannes Eickmans: For a specific planning it is important that the plants are available when they are scheduled to produce. Therefore reliability is important. Another fact is that a worldwide class unit with only one line cannot adapt to changing demand as easily as unit with multiple lines, where single lines can be shut off. In general, new investments in capacity expansions have to be based on good market forecasts and they are long-term decisions. Normally it takes time for the market to absorb the new capacity. we.CONECT: Do you use and / or plan to implement new technologies like MES, Big Data & Cloud Technologies? Dr. Johannes Eickmans: BMS has implemented MES in most of its units and we are continuously updating the systems. We operate in commercial systems and in addition have systems build by our technology provider Bayer Technology Services. Currently we don’t use “Big Data & Cloud technologies” on a large scale. One Big Data aspect is the analysis of production data history with neuronal networks to detect hidden causes for improvement. Cloud technology is a dazzling term and we would have to better define it. Of course we have a globally connected IT infrastructure which we may call “private cloud”. we.CONECT: Do you use mobile technologies to optimize operator management and operator mobility? Dr. Johannes Eickmans: No. In most cases we do not have a WLAN in our units and mobile equipment which is explosion-poof is either too expensive or not available. An additional requirement is the connectivity of the mobile devices with Meridium or SAP. we.CONECT Which role plays the topic critical infrastructures in relation to cyber security in your plant? Dr. Johannes Eickmans: For years this is an important topic and we have measures in place to protect our productions systems, for example multistage firewalls to separate the internet from office PCs, a firewall between SAP or PI an the DCS systems. USB ports are blocked and a strict access right management. We operate in emergency power systems. Another important topic is that all people in the unit are aware of the importance of cyber security. Therefore special online awareness trainings are conducted. we.CONECT: According to your presentation “Implementation of a Global System for Production Loss Accounting”, could you briefly introduce us to the project and what is important about this topic? Dr. Johannes Eickmans: It is important to have an accurate production loss accounting system. This is essential for 5 reasons: 1. to know where the big losses occur, 2. to know the root course of the losses, 3: to guide continuous improvement measures and experience exchange, 4. to set realistic improvement targets and 5. to control the progress. This means in summary to increase the OEE. Easy visual and analytic access to the data is important for a living system. we.CONECT: How different will the Chemical Operations/Manufacturing of the year 2020 be from today’s ones? Dr. Johannes Eickmans: In the chemical industry the conti production is higly-automated. Today’s Operations is basically performed from a central control room using advanced process technology. we.CONECT: Which question would you like to ask the delegates of our Global ManuCHEM Strategies 2014? Dr. Johannes Eickmans: I would be interested in how production loss is counted in other companies. Which software are they using and which KPIs do they define? we.CONECT: Thanks a lot for this interview!
  2. 2. Interview Partner: Peter Haack and Dr. Johannes Eickmans. After studying physics Dr. J. Eickmans worked as a post-doc for 2 years at Yale University, USA before joining the Central Research Department at Bayer in 1987. From 1994 – 1997 he worked in product development at AGFA-GEVAERT, Belgium. From 2001 to 2010 Dr. Eickmans held a Principal position at Bayer Business Consulting. His main areas of consulting have been projects in production, e. g. maintenance strategy, continuous process improvement, cost cutting, personnel efficiency and benchmarking studies. Since 2010 he was responsible at Bayer MaterialScience as Head of Global Operational Excellence. Now he is Head of Change Management for Industrial Operations. Global ManuChem Strategies brings together industry leaders to discuss the current state of the industry, the impact of new regulations and the challenge to increase efficiency in chemical operations and technical assets. Information about the event and we.CONECT can be found at: http://production-chemicals2014.weconect.com about Contact: Henry Fuchs Managing Director / Product Management & Marketing Phone: +49 (0)30 52 10 70 3 – 44 Fax: +49 (0)30 52 10 70 3 – 30 Email: henry.fuchs@we-conect.com we.CONECT Global Leaders GmbH Gertraudenstr. 10-12 10178 Berlin, Germany www.we-conect.com

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