Improvement Leader Development Program (ILDP)

Click here to learn about Improvement Leader Development Program (ILDP)


Key areas for Operational Excellence Transformation

Operational Excellence Transformation is Yokogawa and KBC’s co-innovated portfolio of solutions and services.We provides comprehensive solutions for business automation in all four areas using consulting and digital technology.

Operational Risk Management

Yokogawa's Operational Risk Management deals with managing safety, health and environmental risks on both individual and process levels in a reliable and risk-free manner. It involves the end-to-end process of designing, visualizing and orchestrating plant production and business systems.

Key Operational Competencies in Operational Risk Management

  • Process Safety Management: Maintain License to Operate, preserve Business Reputation, and create value by utilizing and adhering to operating integrity processes to prevent loss of containment or catastrophic loss
  • Personal Safety Management: Protect human assets by providing safe practices to improve behaviour and culture
  • Environmental Management: Provide processes to protect the environment through operating integrity, and ensure compliance with environmental, regulatory and/or internal requirements
  • Community Relations: Define and establish processes and protocols to communicate and implement emergency response plans, and enhance interactions in the community
  • HSSE Reporting and Compliance: Assure visibility and achievement of HSSE goals and compliance requirements, by monitoring, learning and improving continuously through processes, initiatives and KPIs
  • Plant Protocols and Security: Provide processes and strategies to protect assets and infrastructure from threats, and control access to vulnerable processes and equipment

By combining Yokogawa’s product portfolio and KBC’s consulting services, we provide our customers best practices and domain knowledge that empower them to improve their operations, as well as a digital platform that supports such activities and initiatives. Our Operational Risk Management scope does not only cover partial improvements in the organization, but also optimizations in plant operations to achieve continuously improving safety, reliability and operability.

 

·Supply Chain Optimization

- Optimize management of supply, whether oil in the ground or feedstocks for a refinery or chemical asset, in light of product market demands. This provides operators with the agility to take full advantage of market conditions.
·Asset Operations and Optimization
- Optimize the potential of physical assets, by pushing throughput and maximizing the production of the highest value products, whilst minimizing variable costs such as energy.
- Deliver small and large capex projects, on time and on budget, to deliver growth and meet environmental requirements.
·Asset Management and Integrity
- Confidently ensure asset reliability and availability, whilst controlling maintenance costs. This assures the asset always meets expectations and is always available to capitalize on short term market opportunities. 


Improvement Leader Development Program (ILDP)

The Improvement Leader Development program (ILDP) is a training program for the process industries that develops leaders who will engage in continuous improvement programs. A key element of ILDP is virtual on-the-job training (OJT) using a dynamic process simulator and process control system. Participants are able to observe the impact of various improvements activities in real-time.

The ILDP features courses on the following three subjects that are key to achieving continuous improvements: regulatory control optimization, modular procedural automation, and alarm management.

Customer Challenge

Developing Improvement Leaders

  • The increasing complexity of production processes requires improvement leaders who have not only expertise in their own area of responsibility; but also thorough knowledge of the entire plant, the latest standards in the industry, and sometimes best practices in different industries.

  • An organizational silo, which is commonly observed in plant operation today, is considered to be one of the obstacles to the development of improvement leaders.

  • Increasing global competition has encouraged the introduction of continuous improvement programs (CIP), but the number of staff who are able to lead these improvement programs is limited.

Our Solutions

Providing Best Practices for Solving Issues And Nurturing Improvement Leaders

The Improvement Leader Development Program offers an environment in which virtual on-the-job training can be conducted at a desk using a dynamic process simulator.

ILDP is designed to develop the ability to solve real issues by lectures and practices using a virtual plant. First, participants learn about best practices for solving problems in a classroom environment with reference to a wide range of laws, regulations, guidelines, and industry standards necessary for improving operations. Then, they learn how to effectively utilize various methods by repeatedly implementing the various practices learnt into a high fidelity plant simulator and confirm the results of their success (or failure) of implemented measures.

By experiencing a series of problem-solving exercises, participants acquire the knowledge and confidence required to become future improvement leaders.

Topics covered:

  • Alarm Rationalization (FNAR, EASD, OSAM)
  • Modular Procedural Automation (automation of procedural operations) course
  • PID Loop Controllability Improvement course (Regulatory Control Stabilization)

Customer Benefits

More Value Than Just Theoretical Knowlege

Participants acquire practical experience through individual and group exercises in the virtual OJT. Also, Participants are able to develop the necessary skills to lead continuous improvement program using the proven Six Sigma DMAIC approach. This enables them to identify the areas to be improved, and thus achieve improvements in a steady and consistent way.

Some typical feedback from participants in this program is as follows.

"Designing the right alarm system was somewhat difficult for me, but I mostly understood it through this program. Now, I can utilize this experience for improving our plant operation."
(Mr. Masaaki Tanaka, Oita Chemical Co., Ltd.)

"Learned the basic concept of alarm management, with a systematic approach. Course inspires us for plant improvement."
(Teijin Polycarbonate Singapore Pte Ltd, Mr. VT Suresh)

 

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