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KBC ADVANCED TECHNOLOGIESProprietary Information
SUPERIOR RESULTS. SUSTAINED.
What Happens When Your Workforce Retires? Webinar2016
6 October 2016
KBC ADVANCED TECHNOLOGIESProprietary Information
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Your Host Speakers Today
KBC ADVANCED TECHNOLOGIESProprietary Information
Simon AngellSenior Vice President
Regional Sales
6 October 2016
Ching Chye HouSenior Consultant
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Agenda
• Competitive landscape, demographic trends and implications• How are leading companies responding?• Case studies• How KBC assists clients to maintain competitive advantage
KBC ADVANCED TECHNOLOGIESProprietary Information 6 October 2016
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Competitive Pressure from Mega Sites Especially Intense in APAC Region
6 October 2016KBC ADVANCED TECHNOLOGIESProprietary Information
• Secure base plant operation Safe and reliable plant
operation Effective handling of
abnormal situations
• Continuous process improvement and optimisation On-shift Off-shift
Performance Imperatives
Economy of Scale Upgrading Capacity Processing Flexibility
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Plant Demographic Trends Indicate Increased Operational Risk Exposure If Not Handled Well
6 October 2016KBC ADVANCED TECHNOLOGIESProprietary Information
• Are you effectively transferring operational knowledge from the experienced operators?
• How robust is your new hire competency development and assurance process?
• Are your supervisors competent to lead and develop a less experienced workforce?
• With the increased reliance on Advanced Process Control (APC), will your crew be able to handle abnormal situations effectively?
• Is technical expertise in place to support plant optimisation efforts?
Is your plant at risk?
Age
IN 5 YEARS
Age
TODAY
Wave of retirees dilutes operational
experience and knowledge
Increased need for supervisory skills
to lead and develop workforce
Large wave of new operators to be
trained
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How are Leading Companies Responding?
KBC ADVANCED TECHNOLOGIESProprietary Information
Workforce Capability Challenge
Ahead of your competition
Workforce Development
Profit
Revamp training programme to
accelerate operator development
Capture and transfer Operational knowledge
and experience
Develop Technical skills to drive process
optimisation
Develop supervisory skills to promote shift
team effectiveness
6 October 2016
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Revamp Training – Accelerated Operator DevelopmentCore programme design principles
6 October 2016KBC ADVANCED TECHNOLOGIESProprietary Information
• Blended, interactive approach to training• Staged, guided learning paths• Structured coaching/mentoring programme
Trainee Driven Active Learning & Development
• Experiential knowledge transfer must include “why,” not just “what” and “how”
• Experience must be built on a developed predisposition to think; not react
• Structured developmental projects designed to promote experience transfer
Structured Approach to Experiential Knowledge Transfer
• Well defined career maps• Progression paths designed to promote competency
development• Focused developmental assignments
Career Progression Paths
Example Field Operator Training Pathway
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Effective Knowledge Capture
6 October 2016KBC ADVANCED TECHNOLOGIESProprietary Information
Develop situationals to capture and discuss tacit knowledge
• Based on “what-if” scenarios that could occur on the equipment and process
• Designed to facilitate applied problem solving and thereby reinforce the application of underlying competencies
• Focused on operational upset conditions or desired operational changes, leading the trainee through the process of how those conditions/changes should be addressed
Example Situational – Kerosene ASTM Colour Off
Identify the Problem
Determine Potential Causes
Narrow Down
Probable Causes
Draw Preliminary Conclusion
Prove Conclusion
Take Corrective
ActionIdentify Root
CausesDocument Learning
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Transfer of TrainingFull application of new skills and knowledge to the workplace
6 October 2016KBC ADVANCED TECHNOLOGIESProprietary Information
Training Design
Trainee Characteristics
Training Input
Work Environment
Source – Adapted from Baldwin, T.T. & Ford, J.K. (1998), Personnel Psychology, 41(1), p.65
• Ability• Personality• Motivation
• Principles of Learning• Sequencing• Training Content
• Supervisory and Peer Support
• Opportunity to Use
Realised Benefits
Business Performance
Training Output
Learning & Retention
Behavioural Change
On Job Application
Motivational Levers
Supervisory Levers
• Coach trainee on training purpose and objectives
• Address “What’s in it for me?” Demonstrate high job and career utility
• Provide clear performance specifications and consequences
• Provide recognition and feedback
• Build transfer partnership –managers, trainers, trainees
• Take active interest in trainee development
• Provide opportunity to perform• Promote peer sharing• Monitor skill application levels• Coach weak performers
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Develop Technical Skills and ExcellenceHow to develop internal capability to support and sustain plant optimisation efforts?
6 October 2016KBC ADVANCED TECHNOLOGIESProprietary Information
Classroom Training• Technical training• Plant Economics• Software training
On the Job Training
• Technical competency framework • Technical career ladder• Work process optimisation• Service Level Agreements
• Opportunity identification roundtables
• Models development and maintenance
• Opportunity development and implementation
• Stakeholders management
Ongoing Coaching
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Supervisory Skills to Promote Learning Organisation
6 October 2016KBC ADVANCED TECHNOLOGIESProprietary Information
Supervising for Operational Excellence
• Process operators are the single most valuable asset to any production facility, and frontline supervisors are the key to realising that value.
• Supervising for Operational Effectiveness helps supervisors develop the knowledge, skills, and attitudes to succeed.
Course Content1. The process industry2. The process plant supervisor position3. The various aspects of human behaviour4. How to better communicate with employees5. How to effectively solve problems
and make decisions6. How to lead employees in a work
environment7. How to train and develop employees8. How to manage the production plan9. How to manage employee performance
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Supervisory and Management Skills DevelopmentRefining sector case study
Client SituationOperational Excellence performance far below company targets for several years and safety performance being impacted. These resulted in significant opportunity loss. Internal and external analysis found a gap in the present capabilities of existing leaders and supervisors as a main contributor.
Procedures Performed
Outcomes
• Comprehensive Operational Excellence Curriculum with 3 distinct levels for leaders/managers across the organization
• Application of learning (initiative frameworks) linked to direct business results with a focus on Operational Excellence (value realization)
Results • Achievement of direct business results as part of individual improvement initiatives totalling >$6M USD per year as part of pilot program
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Opportunity Identification and Technical Skills DevelopmentRefining Sector Case Study
6 October 2016KBC ADVANCED TECHNOLOGIESProprietary Information
Client SituationA North Asian client was interested in improving their profitability without capital investment. KBC and the client agreed to form a partnership to focus on finding non-investment opportunities to reduce crude oil cost, maximise middle distillate, and save energy. Client’s technical ability to support such initiatives were also developed.
Procedures Performed
• Created process unit simulation models including a “mini” flowsheet around the heavy oil portion of the refinery using Petro-SIM™ to evaluate the technical and economic viability of opportunities. Technical training on the use of the simulation tools.
• Provided documentation outlining the technical background and economic impact of implementing the top priority opportunities
• Assisted the refinery with opportunity testing and implementation
• On-going technical support and coaching
Outcomes
• Areas of opportunity identified include improving FCC yields; improving yields and efficiency of residue upgrading unit; Increasing the Vacuum unit VGO production; improving the Vacuum unit feed preheat.
Results• Improved the refinery profit awareness culture and helped train the refinery engineers on the fundamentals behind opportunity
identification, evaluation, and implementation
• Tested and proven implemented benefits for each of the Year 1 and Year 2 programmes were ~10 times the programme cost
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Summary
KBC ADVANCED TECHNOLOGIESProprietary Information
Workforce Capability Challenge
Ahead of your competition
Workforce Development
Profit
Revamp training programme to
accelerate operator development
Capture and transfer Operational knowledge
and experience
Develop Technical skills to drive process
optimisation
Develop supervisory skills to promote shift
team effectiveness
6 October 2016
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What KBC Offers To Help You Get Ahead Of Your Competitors?
• Independence – a fresh external view and objectivity
• Methodology – to identify, implement and sustain performance enhancing ideas across all key disciplines
• Unique Toolsets – for site-wide analysis of opportunities
• Unrivalled Breadth and Depth of Experience – we have worked with most major refineries in APAC
• Change Management Experience – to facilitate, implement and sustain the changes which increase commercial awareness, deliver best practices and improve operating profits
• Proven Track Record – with clear focus to improve profitability – KBC has been doing this since 1979 through many market cycles
KBC ADVANCED TECHNOLOGIES Proprietary Information 6 October 2016
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Where To Turn For Help?
Access our Global Expertise [email protected]
KBC ADVANCED TECHNOLOGIESProprietary Information 6 October 2016
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Thank you for joining us!
• We welcome suggestions for future topics – please email [email protected]
• Webinar video recording will be sent out shortly
• Please be sure to fill in our short survey after the webinar
• Thank you for joining us and watch out for the next webinar from KBC!
KBC ADVANCED TECHNOLOGIESProprietary Information 6 October 2016
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Thank you for joining us !
6 October 2016KBC ADVANCED TECHNOLOGIESProprietary Information