Huntsman’s Dan Kemp, director of manufacturing for Port Neches Performance Products, encourages his team members to have courage, passion and purpose — to have the courage to call for or make change when something is dangerous or not working, to have a love for or desire to excel at their jobs, and to set and have goals that are not easy but attainable.
“Every site director or plant manager faces different challenges that require different skills to be utilized at any given time,” Kemp said. “My focus is not only on learned skills but also on particular qualities that help me put the appropriate skills to use when needed. Every plant manager must be able to lead and motivate employees, address employee issues, work in a team environment and delegate responsibilities when necessary. Courage, passion and purpose throughout the site will make the Port Neches, Texas, plant a safer place to work and will make me a more effective manager and leader.”
Kemp, who received his bachelor’s degree in mechanical engineering from Oklahoma State University in 1983, began his career in upstream and midstream oil and gas before joining Huntsman in 1998. Kemp has held a number of positions within Huntsman, beginning as superintendent of pipelines and storage caverns at the company’s facility in Port Arthur, Texas. He then served as operations manager of Huntsman’s plant in Conroe, Texas, followed by a role as engineering, maintenance and construction manager of the Conroe and Dayton, Texas, facilities.
Prior to becoming director of manufacturing for Port Neches Performance Products, Kemp served as director of global engineering and maintenance for Huntsman’s Performance Products division. Now, as director of manufacturing, Kemp is responsible for all activities on site including safety and production at Huntsman’s largest plant globally.
“I am conscious I set the tone for everything that happens at the Port Neches manufacturing site so I work hard to empower people through communication, action and systems that reinforce the ideas of courage, passion and purpose,” Kemp said. “At the end of the day, every employee at the facility, and even people in the community, should know we care for their safety and well-being. I believe once people know we care about them, they will care about us.”
Overcoming challenges
The challenges both Kemp and Huntsman face are similar to those being faced industry wide.
“There is always a need for qualified personnel,” he said. “We work extensively with local schools to ensure students are aware of the opportunities a degree in science or engineering offers. Members of our plant leadership team serve on the advisory boards of the local university and technical school, and we contribute considerable time and resources in local high schools that foster science-based learning and extracurricular activities. We also offer internship and co-op programs for people to hone their skills in a real-world setting.
“We face challenges in our operations as well. We spend a lot of time communicating about our process and personal safety programs. These programs are designed to ensure our employees leave work unharmed and return to work unharmed. The programs reinforce the idea we need to be good stewards of the environment by keeping product “in the pipes,” running efficient processes and handling waste properly. I am pleased to say our programs are paying off. In 2005, our Total Recordable Incident Rate was approximately 4.5. For the past three years, it has been 0.55 or better and we were recognized by the Texas Chemical Council in 2012 with a Safety Excellence Award.”
Another challenge is making sure Huntsman produces a quality product in quantities that meet customers’ needs while significantly reducing safety risks.
“We are spending $150 million to increase our ethylene oxide production by 25 percent, making us the largest producer of ethylene oxide in the United States,” Kemp said. “The expansion will add 10 full-time Huntsman positions as well as five to 10 contractor positions on site. Installation alone has created 300 construction jobs. Because we purchased the unit from another facility, we will be able to bring it on line more efficiently with a forecast start-up in summer 2015.
“Around 2006, a string of incidents including a fire at one of Huntsman’s facilities in the area focused the company’s attention on process safety. Huntsman’s senior leadership made a commitment to eliminate or significantly reduce process safety risks and implemented a comprehensive process safety program. Our Port Neches plant served as the company’s flagship location in the new program, which resulted in significant reductions in our personal and process safety incident rates.”
Being a responsible steward
As a company, Huntsman sees its responsibility extending to people, planet and profit. Huntsman has put that vision into action in unique and impactful ways, and is working hard to ensure the company is a responsible steward of its license to operate.
“One of the things I am most proud of is the preservation of the 1,900 acres of wetlands we have on site,” Kemp said. “Some years ago, we began a concerted effort to protect this delicate ecosystem. As a result of our partnerships with Ducks Unlimited and the Coastal Conservation Commission, our wetlands are teeming with native wildlife.
“Middle school and high school biology classes routinely visit us to experience the many different species that thrive in the wetlands. It is gratifying to see how this single program affects all of us. At the plant, we grow more sensitive to the proper use and disposal of resources while countless students learn about plants, animals, complete ecosystems and the importance of protecting the environment.”
Huntsman supports robotics programs in area high schools and serves on engineering and technology boards at local colleges. The American Cancer Association and the local chapter of the United Way are also associations Huntsman serves and where Kemp served as a chairperson for the 2012-2013 campaign.
Kemp currently serves on an American Fuel & Petrochemical Manufacturers committee, allowing him to communicate with peers and gain their perspectives on industry-wide challenges and concerns.
“I also regularly read industry publications like BIC Magazine and spend time reading industry blogs and participating in online forums to stay on top of news in our industry,” he said. “My focus is on ensuring the responsible operation of the facility as well as the safety of the employees and the communities around us.
“As a plant manager with innumerable responsibilities, it is easy to focus exclusively on my own facility. The organizations I am involved with help me see beyond the gates of the plant and explore broader issues where I can have a positive impact. I am active in the Golden Triangle Business Roundtable, Area Plant Managers Forum and the Citizens Advisory Panel. Additionally, I devote time and resources to volunteering with the Boys & Girls Haven, the Jefferson County Local Emergency Planning Committee, my church and local schools’ science programs.”
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Port Neches
Performance Products
Huntsman
2701 Spur 136
Port Neches, Texas 77651
(409) 724-4400
Employees: 600 associates and 500 contractors
Products: Amines, ethanolamines, ethylene, ethylene glycols, ethylene oxide, methyl tertiary-butyl ether, propylene, propylene glycol, propylene oxide and surfactants
Size: 3,000 acres
