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Globalization of the Globalization of the Cytec Product Stewardship SystemCytec Product Stewardship System

CYTEC

Robert D. Crawford

Manager, Global Hazard Communication Programs

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TopicsTopics

Cytec background and organization missionCytec background and organization mission System overviewSystem overview Background/Major ImplementationsBackground/Major Implementations Key business processesKey business processes System functionalities and contentSystem functionalities and content Software improvements/customizationsSoftware improvements/customizations Labeling initiativeLabeling initiative Metrics/Process capabilitiesMetrics/Process capabilities Current initiativesCurrent initiatives

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About Cytec Industries, Inc.About Cytec Industries, Inc. Global specialty chemicals and materials Global specialty chemicals and materials

companycompany Product serving diverse end marketsProduct serving diverse end markets

• AerospaceAerospace• AdhesivesAdhesives• Automotive and industrial coatingAutomotive and industrial coating• Chemical intermediatesChemical intermediates• InksInks• MiningMining• PlasticsPlastics

44 plants and R&D facilities in 19 countries44 plants and R&D facilities in 19 countries ~$3.3B annual sales~$3.3B annual sales

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Product Stewardship & Regulatory AffairsProduct Stewardship & Regulatory Affairs

MissionMission Actively promote the responsible and safe Actively promote the responsible and safe

use of Cytec products around the world use of Cytec products around the world and manage product regulatory and manage product regulatory compliance globally through:compliance globally through:• Corporate StewardshipCorporate Stewardship• SustainabilitySustainability• Regulatory ComplianceRegulatory Compliance• Product Regulatory AdvocacyProduct Regulatory Advocacy• Superior ServiceSuperior Service• Continuous ImprovementContinuous Improvement

WERCS System is a critical tool to support department mission

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Cytec Product Stewardship SystemCytec Product Stewardship System SoftwareSoftware

• WERCS = Worldwide Environmental WERCS = Worldwide Environmental Regulatory Compliance SolutionsRegulatory Compliance Solutions

Overall useOverall use• Store and maintain product HSE data to Store and maintain product HSE data to

protect human health and the protect human health and the environmentenvironment

• Comply with global chemical regulationsComply with global chemical regulations• Provide product information in the form Provide product information in the form

of SDS’s and labelingof SDS’s and labeling• Interface with other systemsInterface with other systems

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Background/Major ImplementationsBackground/Major Implementations Evolution from paper to database systemsEvolution from paper to database systems Original Wercs implementation (Aug 2002)Original Wercs implementation (Aug 2002)

• Migrate from homegrown legacy systemMigrate from homegrown legacy system• Meet functionalities of old system and add new Meet functionalities of old system and add new

needed functionalitiesneeded functionalities• Electronically migrate 60 years worth of Electronically migrate 60 years worth of

Cyanamid/Cytec data and documentsCyanamid/Cytec data and documents Second implementation (Dec 2006)Second implementation (Dec 2006)

• Integration of UCB Surface SpecialtiesIntegration of UCB Surface Specialties• Migrate from SAP EHS and other homegrown Migrate from SAP EHS and other homegrown

systemssystems• Establish interface to SAP ERP’sEstablish interface to SAP ERP’s

Software Improvements/CustomizationsSoftware Improvements/Customizations Global Labeling ProjectGlobal Labeling Project

Cytec WERCS System has globalized as our business has grown

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System Globalization Drivers and ProcessSystem Globalization Drivers and Process

Strategic review of business needs versus Strategic review of business needs versus systemssystems• Homegrown system would not meet future Homegrown system would not meet future

needs without major redesignneeds without major redesign• Move to “off-the-shelf” commercial softwareMove to “off-the-shelf” commercial software

Rigorous process/Partnership with ITRigorous process/Partnership with IT• System reviews and selectionSystem reviews and selection• Requirement definitions and contractRequirement definitions and contract• Detailed project planningDetailed project planning• Weekly status review with senior managementWeekly status review with senior management

Both implementations delivered on-time Both implementations delivered on-time and budgetand budget

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Overall Product Stewardship Business ProcessOverall Product Stewardship Business Process

Cytec Policy – No product can be Cytec Policy – No product can be manufactured or sold without a PSCF/AMA manufactured or sold without a PSCF/AMA and approved MSDS and Labeland approved MSDS and Label

PSCF (Product Stewardship Compliance PSCF (Product Stewardship Compliance Form) and AMA (Additional Material Form) and AMA (Additional Material Approvals)Approvals)• Assign codes to enable setup in ERP systemsAssign codes to enable setup in ERP systems• Assess hazardsAssess hazards• Determine regulatory classificationsDetermine regulatory classifications• Prepare SDS and LabelPrepare SDS and Label

System directly supports our key business process

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Key System FunctionalitiesKey System Functionalities

Globally accessible and secureGlobally accessible and secure Flexible to add new fields, languages and Flexible to add new fields, languages and

create new format SDS’screate new format SDS’s Intranet accessIntranet access Interfaces with ERP systemsInterfaces with ERP systems

• Product labelingProduct labeling• Gate-keeper/products to regulated countriesGate-keeper/products to regulated countries• SDS distributionSDS distribution

Electronic PSCFElectronic PSCF

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System Data Content OverviewSystem Data Content Overview

Product business informationProduct business information Detailed compositionDetailed composition Manufacturing informationManufacturing information Toxicology & environmental dataToxicology & environmental data Chemical, physical, and other propertiesChemical, physical, and other properties Regulatory classificationsRegulatory classifications SDS/Label documentsSDS/Label documents Chemical component dataChemical component data

System contains much more than just MSDS data

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Products and DocumentsProducts and Documents

Approximately 20,000 active Approximately 20,000 active materials including:materials including:• Commercial productsCommercial products• R&D samplesR&D samples• IntermediatesIntermediates• Raw materialsRaw materials• WastesWastes

Another 20,000 “inactive” materialsAnother 20,000 “inactive” materials

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SDS and LabelsSDS and Labels System contains ~90,000 active SDS and LabelsSystem contains ~90,000 active SDS and Labels Currently published in 34 formats and 22 Currently published in 34 formats and 22

languages including Chinese, Japanese and languages including Chinese, Japanese and KoreanKorean

Major FormatsMajor Formats• USUS• CanadaCanada• EUEU• AustralianAustralian• Mexican/Latin AmericanMexican/Latin American• JapaneseJapanese• Asia/PacificAsia/Pacific

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Software Improvements – 1st ImplementationSoftware Improvements – 1st Implementation Custom product selectCustom product select GenericsGenerics Powerwercs formatter and editorPowerwercs formatter and editor PSCFPSCF Ad-hoc reports for WebAd-hoc reports for Web Phrasewercs (copy & “buddy languages”)Phrasewercs (copy & “buddy languages”) Validation for missing phrase translationsValidation for missing phrase translations CD WriterCD Writer Formulation data (FTXT/FVAL)Formulation data (FTXT/FVAL) ModelsModels SQL based rulesSQL based rules Faxback systemFaxback system TSCA12bTSCA12b OPITOPIT

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More Improvements between Major More Improvements between Major ImplementationsImplementations

PSCF/PowerwercsPSCF/Powerwercs• Display and print bill of materials for Display and print bill of materials for

manufacturing formulation (XBOM)manufacturing formulation (XBOM) Author/PowerwercsAuthor/Powerwercs

• Allow selected subformats to override Allow selected subformats to override automatic chemical name maskingautomatic chemical name masking

TranslationsTranslations• Improve validation program to detect missing Improve validation program to detect missing

phrase translations for component dataphrase translations for component data Print QueuePrint Queue

• Batch Publishing/PrintingBatch Publishing/Printing

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Software Improvements – 2nd ImplementationSoftware Improvements – 2nd Implementation Product checkout (block publishing)Product checkout (block publishing) PDF archivePDF archive Published document screenPublished document screen

• Screen size scalability and hide unauthorized documentsScreen size scalability and hide unauthorized documents InterfacesInterfaces

• MSDS distribution – 3 SAP instancesMSDS distribution – 3 SAP instances• Dangerous goods – 1 SAP instancesDangerous goods – 1 SAP instances• Material master – 3 SAP instancesMaterial master – 3 SAP instances• PLIMSPLIMS

Product searchProduct search• Search on aliasesSearch on aliases• Checkbox to hide aliasesCheckbox to hide aliases

Phrasewercs – screen level securityPhrasewercs – screen level security PSCF program – new fields, reorganizePSCF program – new fields, reorganize

Continuous improvement facilitates our capability to support business

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Global Labeling ProjectGlobal Labeling Project

Objective:Objective:• To implement a global labeling To implement a global labeling

solution (process, ownership and solution (process, ownership and tools) that will meet the requirements tools) that will meet the requirements of customers, business units, of customers, business units, manufacturing and satisfy regulatory manufacturing and satisfy regulatory needs. needs.

• The solution must integrate BPCS with The solution must integrate BPCS with Cytec WERCS MSDS. Cytec WERCS MSDS.

• In addition it will centrally integrate In addition it will centrally integrate regional, local, customer and business regional, local, customer and business information not currently in either information not currently in either BPCS or WERCS. BPCS or WERCS.

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ScopeScope All Specialty Chemicals business units and All Specialty Chemicals business units and

customerscustomers All plants, distribution centers, tollers, re-packers All plants, distribution centers, tollers, re-packers

and resale sourcesand resale sources All bulk and packaged finished commercial All bulk and packaged finished commercial

products (generic and specific, 3rd party, etc.)/ products (generic and specific, 3rd party, etc.)/ excluding R&D samplesexcluding R&D samples

Labeling processes for preparing and maintaining Labeling processes for preparing and maintaining preprinted packagespreprinted packages

All countries and languages necessary to meet All countries and languages necessary to meet sales and regulatory requirementssales and regulatory requirements

All customer specific requirementsAll customer specific requirements All other current label inclusions (e.g. Kosher, NSF, All other current label inclusions (e.g. Kosher, NSF,

gross/tare/net in lbs/kilos, lot numbers, trademark, gross/tare/net in lbs/kilos, lot numbers, trademark, care and feeding directions, etc.)care and feeding directions, etc.)

May be exclusions for non-BPCS sites and special May be exclusions for non-BPCS sites and special regulated products such as pesticidesregulated products such as pesticides

Labelwercs is the selected solutionLabelwercs is the selected solution

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Drivers of ChangeDrivers of Change Problems with incorrect labeling and late Problems with incorrect labeling and late

shipmentsshipments Obsolete and fragmented global labeling Obsolete and fragmented global labeling

systems not linked to SHE or BPCSsystems not linked to SHE or BPCS Labor intensive to integrate acquisitionsLabor intensive to integrate acquisitions Inconsistent label content, design and Inconsistent label content, design and

ownership of data globallyownership of data globally

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BenefitsBenefits Improved Customer SatisfactionImproved Customer Satisfaction

• Facilitate better labeling and shipping Facilitate better labeling and shipping practicespractices

ReliabilityReliability• Consistent and stable global solutionConsistent and stable global solution

FlexibilityFlexibility• Ability to increase our label service offeringAbility to increase our label service offering• Easily expandable for future growthEasily expandable for future growth

Accuracy / ConsistencyAccuracy / Consistency• Reduced regulatory compliance riskReduced regulatory compliance risk• Consistent label content sourceConsistent label content source• Consistent global processes, systems and Consistent global processes, systems and

ownership of dataownership of data

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Product Label – “Document affixed to a container which identifies the product, responsible company, and provides appropriate precautionary warnings which describe hazards and safe handling measures. Product Labels also contain chemical component data and other information required by our businesses, plants and customers.” The Product Label has been divided into a number of “Sub Labels” which are areas reserved for a particular collection of information. Sub Labels can exist and be affixed to a container as separate documents or may be incorporated within a single Product Label.

Regulatory Sub Label•Company logo•Company name, address and emergency telephone number•Product name•Precautionary warnings and handling measures•First aid•Chemical components•Container warnings•Hazard Symbols

Business Sub Label•Directions for use or storage requirements•Patent statements•Slogans•“Quasi-regulatory” information such as

NSF or Kosher marks

Transportation Sub Label•Transport symbol•UN Number•Proper shipping name•Technical description•Flash point

Customer Sub Label•Customer codes•Bar codes•Customer name and address•Hazard Ratings (e.g., HMIS)

Manufacturing Sub Label•Batch or Lot number•Bar code•Expiration date•Country of origin

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Technical OverviewTechnical Overview Labelwercs softwareLabelwercs software

• Design and render labelsDesign and render labels Overall Wercs system hosts regulatory label dataOverall Wercs system hosts regulatory label data Front end based on VBFront end based on VB

• Enforces business rules, validations and ties Wercs data Enforces business rules, validations and ties Wercs data to ERP (BPCS)to ERP (BPCS)

Wercs Label templatesWercs Label templates• Templates designed in accordance with regional Templates designed in accordance with regional

regulatory requirementsregulatory requirements• Scripts attached to retrieve ERP dataScripts attached to retrieve ERP data

Color laser printersColor laser printers Polyester label stockPolyester label stock Order scenario automatically generates label Order scenario automatically generates label

using appropriate template and language'susing appropriate template and language's

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ImplementationImplementation

Phased implementationPhased implementation• Started April 2006 - US plants and Started April 2006 - US plants and

distribution centersdistribution centers• June 2006 – CanadaJune 2006 – Canada• July 2006 – AustraliaJuly 2006 – Australia• January 2007 – US tollers and US plants January 2007 – US tollers and US plants

from UCB acquisitionfrom UCB acquisition• China, Europe and other regions in-China, Europe and other regions in-

progressprogress

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MSDS Production MetricsMSDS Production Metrics

Use data generated from Wercs to keep Use data generated from Wercs to keep metrics on our production processesmetrics on our production processes

Key measures include:Key measures include:• SDS/Labels publishedSDS/Labels published• PSCF cycle timePSCF cycle time• Performance against due datesPerformance against due dates

Continue to use Six Sigma tools to Continue to use Six Sigma tools to understand and improve our processesunderstand and improve our processes• Control charts, thought-maps, value-stream Control charts, thought-maps, value-stream

mapping, process mapping, relationship mapping, process mapping, relationship diagramsdiagrams

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SDS Production - 2006SDS Production - 2006

Cytec MSDSs/Labels Published - 12 Months Running

0

1000

2000

3000

4000

5000

MSDSs (6,725 YTD) 763 1230 806 1253 1047 519 5063 1636 2512 1392 3422 1911

Labels (5,812 YTD) 579 957 714 1242 960 799 5340 1263 948 964 3414 1434

Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar

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Process Capability – PSCF cycle timeProcess Capability – PSCF cycle time Control chart shows turnaround time for each requestControl chart shows turnaround time for each request Upper/Lower control limits (UCL/LCL) represent Upper/Lower control limits (UCL/LCL) represent

normal process variationnormal process variation All normal requests expected to fall within rangeAll normal requests expected to fall within range Current Process capability of 21 days based on UCL Current Process capability of 21 days based on UCL

with a turnaround average of 10 dayswith a turnaround average of 10 days

0

5

10

15

20

tim

e (

days)

9 18 27 36 45 54 63 72 81 90 99108 126

Sample

Avg=10.25

LCL=-0.55

UCL=21.04

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Current InitiativesCurrent Initiatives

REACHREACH GHSGHS Continue automated labeling roll outContinue automated labeling roll out Additional interfacingAdditional interfacing More data automationMore data automation

Questions???Questions???