How Process Mining Compliments Productivity Management at WACKER

Wacker is a German chemical company that produces silicone rubbers, polymer products, biotech solutions, and polysilicon and wafers for the semiconductor industry. Minh Chau Nguyen is a digitalization manager and Klaus Kühnel is a project and program management practitioner at Wacker.

Minh Chau and Klaus have seen how process mining complements existing analysis tools in the toolbox of a productivity manager in the era of digitized industries. They showed two concrete cases from analyzing the polysilicon production process at Wacker. One of the projects has resulted in saving the company 17 million Euros per year and the other one lead to a cost reduction of 400 thousand Euros per year.

1. EATING TOMORROW'S SOLUTIONS

How Process Mining Complements Productivity Management at WACKER
Wacker Chemie at Process Mining Camp 2021

7 € se ™

2. Construction Agriculture Food Supplements

3. MS GESELLSCHAFT FUR ELEKTROCHEMISCHE INDUSTRIE GIE H aml

4. Downstream Products

Raw Materials Upstream Products

ethylene (

Disp

Ba Viny! acetate monomer (VAM)

sible polymer powders (DPI

Polyvinyl acetate (PVAc)

ESS | Fo

Customers’ Industries

> Construction, automotive suppliers,
paints and coatings
Textiles, print and paper

> Personal care

>| Solar wafers, cells and modules

> Semiconductors

Engineered fabrics, adhesives, coatings,
carpets

Construction, renovation, insulation.

Food, automotive

5. Our Search for Insights Led Us to...

6. WACKER

The Polysilicon Division

7. POLYSILICON
No. 1 in merchant market

€300 mn [23% of Wacker]
in Q1/2021

POLYMERS
No. 1

OTHERS

En, SILICONES
€4.7bn No. 2

€1.3 bn
in Q1/2021

BIOSOLUTIONS

Leading in niches

8. Office Locations, Sites and Nameplate Capacities*

© Production site and head office
© Sales and application representatives
Production site $

9. United States

10. Silicon — 2" Most Abundant Element in the Earth‘s Crust (26%)

Quartz (SiO) Si-Metal Polysilicon

14. Polysilicon: Starting Point of the ...

... Electronic
Value Chain

Wafer Device “Chip” Electronics

.. Key Raw Material
for > 90% of all

Solar
Systems

Module System

15. Productivity Management

Niveau / Performance
of the system

Systemn System n+1

Fundamental limit of capacity in system n

x
[ES

15
ES PROCESS

o MINING

16. > First Example:

Poly Deposition

17. Polysilicon Production Is a Four Step Purification Process

E Trichlorsilane Trichlorsilane Y Polysilicon Final Treatment
Production Purification Rod Deposition bs (Crushing,
En (Fwidized Bed Reactor) (Distilation) (Siemens Process) Cleaning)
Si+ 3HCI—> HSICh + Ha SICK > Si+ 3 sicl,+ 2H
moi

18. What are
the
questions?

Which data are available
tome?

How can | prepare this?

+
+
=

19. Define

IE EQUI NAME _ ORT NAME

o 0 8

à = 01 LP

8 Bohrmaschine 01 LP 0 How can | condense the data?
o D 06

5 01 LP

20. V1 Aled Woe Sd 3

| ‘wig Buydu ouom Y 1 290" NV. E

=f

o V1 Alod Woes HO Y

=a (v 1) ua60z06 ouoW aes ZZIV La! El E

11
ii

il
m

11051.

WEIS PV Lal E

21. New View on Process:
PROCESS MAP

22. w VS
=»

(1) Data basis fixed (2) Transparency with mining (3) Detailed analyses using statistics

24. Polysilicon Deposition Process

Task:

Where do the
different outputs of
the individual
Deposition halls
come from?

Situation:

The 16 main process steps
of all systems worldwide
are selected from the DB

over 24 months and
analyzed with process
mining

25. Extraordinary process:

Deposition Ñ Slalom

552 Starts Process Process
= 100 %

=

(© 100 %

N regularway /

26. Extraordinary process:
Process is shorten by

Deposition Slalom
Process | Process

27. By Following And Comparing The Tracks,
Significant Successes Could Be Achieved

Saving 1 hour of
process time in all
214 systems results
in annual savings of
17 ME per annum

28. > Second Example:

Physical Analytics
of Polysilicon

29. Task:

The higher quality
requirements must be carried
out with the same measuring
equipment in the same time.

Situation:
55 analysts work on an average of
250 samples on 97 measuring
devices in 5 shifts

30. Raw data form DB
here 206 days> 65,300
individual campaigns

+

WSA manual activity
handwriting every single process

1. Collect and compress data
2. Analysis of the entire area

using SixSigma tools such as

# Work step analysis WSA
# Value stream analysis VSA
# Process Mining / Simulation

3. Synthesis of potentials

Visualization of the current state
and deriving potentials

through the outside view of OE-PM
under consideration of
dimensions:

a) Time
b) Location

©) Manufacturing area
d) Qualification

31. 0. Value Stream Analysis for the global understanding

32. 1.1
. Database selection

ert

1 code

je macros create functiona
s pivot_index() (begin+( in)/2)
t) a), (ape) et!

suaplarD»
end) {

33. ome TARO on Pay Ta 5 ‘20320083819 020320008385

Raw data from DB

here 206 days> 65,300 individual campaigns

Taunus PSTTA SUN (TA) Poy 2 ROO SRS 003 200070059

Bereich _ [Labor [reilbereich frätigkeit Prozessaufwand | Jozessaufwalssaufwand......, pzessaufwakessaufw[ozessaufwabzessaufwa
[min] [min] {min} [min] [min] [min]
[Testabscheid ES A E] GT] 308] 6565]

WSA manual activity
handwriting every single process

[Vorbereitung gebohrte 24] 12 12| ol 0 17,1 29
Proben. 241 Probenätze |Proben anlegen 2] 7 2] 2] 1.00] 09 0.9)
[Proben anschleifen] EE 5] 3] 100]

Company Profa - Corporate Communications 5
Maren

34. 2. Process Mining

35. 3.1. Visualization of Current and Alternative Situations

TEMPERING
o La ROD_ETCHING
= ¡de POLISHING
7 8 9
DRILLING

CUTTING

20 21 22 2
Company Pro Canon Conmunatone .

36. Result:
Due to the
redistribution of the
work between the
work areas and the

scheduling,
5 workers could be
moved to other
production areas!

400 T€ per annum

3.2. Quantification of the measure

37. Other projects that are in progress or planned

2 es GS Ge © oe

Poly cleaning input material delivery behaviour from BGH, NUN and CHA
Rod removal allocation status in the different sites and deposition halls

Rod carriers movement cluster of each ASL

HU based lot-tracking from ASL‘s and ABL through Poly cleaning shop floor
Box on pallets move-status from decanting to quality control
Process-carrier mining between QK and cleaning equipments RL2/ 4
Improvements of Warehouse activities and workflows / on-site trans]
Workflow improvements workshop and equipment cleaning CHA

Reactor rebuilt optimizations CSR/Conversion on all sites

38. Productivity Management

/ PROCESS
afer MINING

N

‘
ES

Summery of ...

Process Mining
at Wacker
in productivity management

is

+ located as one tool in
development and improvement
cycles

and

+ gives a Value-adding Contribution

in combination with the SixSigma
and Reporting applications

39. SUMMARY

40. 1. Very interesting and profitable addition

41. 2. Does not replace the task definition

42. 3. Data preparation needs to be taken into
account

43. 4. Visualization is an excellent aid in
developing improvement ideas

44. 5. Process mining does not replace
experience

45. 6. Social competence needed for personas
related evaluations P

46. Thank you for your attention.

E >