DuPont Operations Manager, Paul Kirkpatrick, discussed DuPont’s step change in performance at the 2015 European Manufacturing Strategies Summit. Watch this presentation for an inside look at DuPont’s journey to world class.
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DPS: DuPont Production System- The Maydown Case Study
Introduction
DuPont Today
Embedding the culture for sustainable improvement
Transferring the Skills To Line Leadership
Regenerating The Vision
Effective Organisational Change
4. 3
11/4/2015 3
First, my self-intro:
I’m a native Irishman born in Belfast in the swinging sixties,(big
birthday in December!!)
I studied mechanical engineering and eventually expanded my
experience in manufacturing having held various roles with DuPont
in Technical , Quality, Projects & Engineering roles . For the past 6
years I have been leading a highly successful implementation of
the DuPont Production System at Maydown in N.Ireland.
5. 4
DPS: DuPont Production System- The Maydown Case Study
Introduction
DuPont Today
Embedding the culture for sustainable improvement
Transferring the Skills To Line Leadership
Regenerating The Vision
Effective Organisational Change
7. 6
Our Core Values Are More Than Just
Goals
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They reflect the way we work and how we operate every day – with our customers,
with our partners from around the world, and in the communities in which we
operate.
DUPONT
CORE
VALUES
SAFETY & HEALTH
ENVIRONMENTAL
STEWARDSHIP
RESPECT FOR
PEOPLE
HIGHEST ETHICAL
BEHAVIOR
Committed to Zero
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DuPont Has Evolved Over Two Centuries
8
EXPLOSIVES
CHEMICALS
INTEGRATED
SCIENCE
1935 – NYLON®
1936 – LUCITE®
1903 –
EXPERIMENTAL
STATION
1915 – PLASTICS
1917 – MAKING DYES
1880 –
FIRST
DYNAMITE
1802 –
E.I. DUPONT
1961 – TEDLAR®
1962 – LYCRA®
1965 – KEVLAR®
1952 – MYLAR®
1923 – CELLOPHANE®
1924 – RAYON®
1924 – FILMS
BUSINESS BEGINS
1928 – CHEMICAL
EXPANSION
205020001950190018501800
1949 – ENGINEERING
POLYMERS
1986 – CORIAN®
2003 – SOLAE JOINT
VENTURE
1966 – TYVEK®
1967 – NOMEX®
1972 – ELECTRONICS
EXPANSION
2000 –
SORONA®
BIO BASED
POLYMER
1805 – CORE VALUES
1804 – FIRST
POWDER MILL
1999 – ACQUIRES
PIONEER HI-BRED
2011 – ACQUIRES DANISCO
2012 – ACQUIRES 100% OF
SOLAE
2013 – COMPLETES SALE OF
PERFORMANCE COATINGS
BUSINESS
2015 – SPIN-OFF OF
CHEMOURS
The DuPont Oval Logo, DuPont™ and all products denoted with ® or ™ are registered trademarks or trademarks of E. I. du Pont de Nemours
and Company or its affiliates.
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Where DuPont Has Unique Opportunities & Advantages
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• Large, attractive markets that reward
innovation
• Clear global trends driving strong
underlying market growth
• Rich set of specific growth
opportunities, both near and long-term
• Leading market positions based on
science
• World class innovation platform, global
brand, customer relationships and
developing market infrastructure
• Unique set of capabilities which enable
the development of bio-based
industries
Robust Opportunities Strong Competitive Advantages
Agriculture
& Nutrition
Bio-Based
Industrials
Advanced
Materials
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Portfolio
Competitive
Position #2 Globally #1 Globally #1 Globally
Potential
Addressable
Market (2020)
~$200B+ ~$50B+ ~$75B+
Projected
Revenue Growth
(2014-2020)
29% + 130% + 35% +
Key Growth
Drivers
• Higher ag productivity
• Food safety & security
• Health & wellness
• Advancements in
biosciences
• Government
regulations
• Lighter transportation
to reduce emissions
• Alternative energy
• Smaller/faster/more
powerful devices
• Increasing need for
protection
Driving the Next Bold Step-Change in
Growth
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Agriculture
& Nutrition
Bio-Based
Industrials
Advanced
Materials
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DPS: DuPont Production System- The Maydown Case Study
Introduction
DuPont Today
Embedding the culture for sustainable improvement
Transferring the Skills To Line Leadership
Regenerating The Vision
Effective Organisational Change
16. 17
170 employees
Only European Kevlar® plant
Significant product &
Technology Base
Global leader in productivity
DuPont Maydown
https://www.youtube.com/watch?v=na16Zv
h2i3A
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We achieved all time record results since 2009
Zero Safety incidents
Record quality performance
Record productivity performance
Performance Productivity improved by 20%
Set-UP Time Improvements
Total contribution of $1.5MM pa through
quicker transitions.
Record Volumes
Increase capacity release leading to record
production volumes
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There is no one silver bullet:
Achievements realised through a balance of projects
Capability
Building
Performance
Management
Organizational
improvement
Mindset and
Behavior
Cause
Mapping
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DPS: DuPont Production System- The Maydown Case Study
Introduction
DuPont Today
Embedding the culture for sustainable improvement
Transferring the Skills To Line Leadership
Regenerating The Vision
Effective Organisational Change
22. 24
Effective Organisational Change
Organisational Change needs to be focussed on the
WHAT
The WHAT should lead the WHO & WHEN
New practices may need new roles do not shy away
from adding roles especially at the value add stage
In most cases the overall return should far outweigh the
initial investment
PRACTICES
PERFORMANCE
STRAGGLE
RS
CAN'T GO THE
DISTANCE
CONTENDERS
PROMISING
BACK OF THE
PACK
1 53
X
Y
42
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DPS: DuPont Production System- The Maydown Case Study
Introduction
DuPont Today
Embedding the culture for sustainable improvement
Transferring the Skills To Line Leadership
Regenerating The Vision
Effective Organisational Change
24. 26
After Deployment…Sustaining DPS
DPS Deployment Team
DPS- ALL Site Personnel
Start Initial Deployment Turnover
Upon kick-off, DPS must drive progress… …allowing site personnel to take full
ownership at roll-out
DPS deployment team role
• Communicate DPS vision
• Set workplan and run learning events, kaizen events,
etc.
• Align necessary resources
• Train site personnel to lead initiatives and institute
process for continuous improvement
Site personnel responsibility
• Participate in problem solving
• Capture opportunity value
• Internalize DPS vision
• Become an agent of continuous improvement
DPS deployment team role
• Facilitate problem solving
• Assist leadership in aligning resources and removing
obstacles
Site personnel responsibility
• Maintain continuous improvement (CI) focus
• Uncover new opportunities
• Prioritize CI initiatives based on business strategy
• Facilitate problem solving teams
• Execute From-To Action Plan
• Communicate. Communicate. Communicate.
DPS Sustainability = Line-led Transformation
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DPS Team
DPS- ALL Site Personnel
Time
Huge benefits attained from Assigning people in key roles in Short term DPS assignments
Production
Leader
Maintenance
Leader
Technical Leaders
People
Leaders
26. 28
DPS: DuPont Production System- The Maydown Case Study
Introduction
DuPont Today
Embedding the culture for sustainable improvement
Transferring the Skills To Line Leadership
Regenerating The Vision
Effective Organisational Change