A a r r O O technical_conference_031499 OSI Software, Inc PI System Users’ Conference Monterey,...
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Transcript of A a r r O O technical_conference_031499 OSI Software, Inc PI System Users’ Conference Monterey,...
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OSI Software, IncPI System Users’ Conference
Monterey, California
POLIMERI EUROPAAN ENICHEM | UNION CARBIDE VENTURE
Ing. Carlo Volpones
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Taking SAP to the Factory FloorTaking SAP to the Factory Floor an an
Italian ExperienceItalian Experience
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Agenda
• Company Profile
• Program Opera
• Management and Technology Challenge
• Company Key Decisions
• Implementation Partners
• Manufacturing Implementation
• Conclusion
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Company Profile
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Polimeri Europa s.r.l.
• Formed in April 1995, Polimeri Europa is a 50:50 Enichem/Union Carbide venture for the development, production, marketing and sale of polyethylene and olefins in the European market
Year 1995 Year 1999
• Sales Revenue 1.4 1.6 Billion USD
• Total Capacity 1,400 1,600 Polyethylene
kty 600 600 Ethylene kty
• Employees 1,626 1,571
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Polimeri Europa Principal Manufacturing Facilities
Brindisi
Ferrara
Priolo
Dunkerque
Oberhausen
Gela
Ragusa
Eschborn
Milan
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Key Investments for the Polimeri Europa Joint-Venture
• Brindisi UNIPOL Project– to take maximum advantage of the product and process
capabilities of UNIPOL technology
• Program Opera– to achieve a substantial business performance improvement
through investment in:• IT architecture and application• Organization / work process redesign• People (skills and training)
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Brindisi Project
• Start date 1st January 1995• Completion date 1st September 1997• Total investment greater than xx million USD• Technology UCC Gas Phase• Total capacity 400 Polyethylene kta• Production lines 2 lines• Type of products LLDPE-HDPE• Customer satisfaction High Level of Acceptance
• First company implementation of OSI, RTDBFirst company implementation of OSI, RTDB
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Why The Word “OPERA”?
• Opera It’s an Italian word known in all the world.
• Opera It belongs to the musical language and reminds “harmony”.
• Opera This word expresses the idea of “working group”.
• Each Opera is one and only.
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Program Opera Objectives
• Create Business Value by:
• improve customer service
• improve efficiency and effectivness of company operations
• improve flexibility and response time to satisfy emerging business needs
• Using a Program Approach that incorporates:
• business process redesign
• implementation of a core information system (SAP) and integrated scientific systems (RTDB)
• training and personnel development
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Program Scope
Geography
ItalyFrance
Germany
Process Application Solution
SAP R/3 Standard vers. 3.1
FI EISQM CO/CCAPS PM
TR HRWM AASD SD SHP
IM MMPP-PI LC
Scientific Systems and
Niche Applications
RTDB
LIMS
SCM
Transportation
Executive
Business Infrastructure
FulfillDemand
BalanceSupply &Demand
CreateDemand
ServiceCustomer
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Management and Technology Challenge
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Management Challenge Assessment of Current Situation (Starting Point Fall 1996)
• Work Processes
– Complex, Not Well Integrated Across Functions Or Locations
– Real Time Information Not Available For Rapid Decision Making
– Require High Levels Of Personal Experience
– Require Significant Duplication Of Effort And Reentry Of Data
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• Systems Slow Response Time and Some Information Not Accurate or Up to Date.
Little Integration of Applications Between Plant Sites and French and German Affiliates.
Very Difficult to Modify Applications to Meet Emerging New Needs.
Limited Access and Experience with Process Control and Data Collection Applications
Technology Challenge Assessment of Current Situation (Starting Point Fall 1996)
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Company Key Decisions
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Company Key Decisions
• Implement common work processes throughout Polimeri Europa.
• Utilize integrated business software (SAP) installed without modifications (standard).
• Use of a Managing General Contractor (Ernst & Young) to deliver project results.
• Implement the project as rapidly as possible to minimize business risk.
• Use standard scientific applications at all sites with certified SAP interfaces.
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Polimeri WAN
Brindisi
Ferrara
Priolo
Gela
Ragusa
Paris
Dunkerque
Eschborn
IT Company Infrastructure
Milan Head Office
Public Network
Router
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Business Integration Using New Applications
Distribution centers
Company code
Head office
Customer
Transportorder
Productionorder
Factories
Stock
Local offices
ProfitCenter
Material
WarehousesMessage/EventHandler
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Implementation Partners
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Implementation Partners
(MGC)(MGC)
Hewlett PackardHardware and system software
OSI (Synapsis)RTDB
Ernst & YoungManaging General Contractor
Polimeri Europa• Head office• 7 plants• many warehouses
OSI (Synapsis)
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Defintion of Operations Work Processes
HS&EHS&EMaintenanceMaintenance Manufacturing Manufacturing
Sub Processes
• Plant line schedules
• Prodcution
• Quality Control
Sub Processes
• Plan & ScheduleMaintenanceActivities
• Execute MaintenanceActivites
• Maintenance
Engineering
Sub Processes• Environmental
Compliance• Process Safety
•
Product Safety•
Personnel Safety
ManufacturingProcess Technology
and Engineering
• Process Enigineering
• Technology Development
• Engineering
Sub Processes
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Manufacturing
Implementation
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Polimeri Europa Plant Overview
• Fully integrated plant facilities located at Brindisi and Dunkerque that manufacture both ethylene and polyethylene.
• Other PE sites (Ferrara, Gela, Ragusa, and Priolo) manufacture only polyethylene from purchased raw materials.
• Plants are generally, round the clock batch and continuous operations
• Finished product is packaged and sold to customers in batches
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Overarching Considerations for the Implementation
• No duplication of SAP - scientific system data input activities in the Control Room during normal shift operations
• Warehouse inventory data must be available real time and updated automaticaly
• Plant operators have one and only one interface for data input
• Production Planning is compiled at headquarters with detail execution at the plants
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SAP Modules Utilized for theIntegrated Manufacturing Solution
• Controlling and Financial Modules for business decision making
• Manufacturing Quality and Material Management Modules for plant operations
› SAP MM and WM for plant material acquisition and movements
› SAP PP-PI for Production Planning and Production Order tracking
› SAP QM for Quality Management of RawMaterial, Packaging and Finished
Product
› SAP CO and FI for product cost and campaign control
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SAP Configuration Design Parameters
• In SAP, plants are modelled as batch units
• For costing purposes, batches of finished product are aggregated into production campaigns
• A plant production campaign is represented in SAP as a Production Order
• Plants are represented in a simplified form in SAP as macro operations
• A plant production cycle is divided in logical SAP Phases
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Framework Used in Developing the Integrated Manufacturing Solution Model
• Production managed as campagins : production quantities calculated of materials consumed and resources utilized for each finished product.
• Economic analysis (cost summaries, and efficincey analysis versus plan) by single campaign and by unit line (on a monthly basis)
• Verification of material and resource availability relative to production orders
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Framework Used in Developing the Integrated Manufacturing Solution Model (continued)
• Advancement of production interfacced with RTDB
• Available to Promise (ATP) updated in real time with planned transfers relative to production orders.
• Raw material to finshed product lot testing traceability
• Finished product lot to lot test traceability
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Tracking Production Advancement using RTDB - SAP Integrated Application Solution
RTDB SAP PP_PI
SAP FISAP MM
Production CampaginLot Traceability Reports
Production Campaign Cost Reports
Finished Product lot tested transfersConsumption (actual and std.) raw material (by lot and non)
Phase Closure
Information from RTDB :.) Finshed lot Product tests..) Quantity of Finished product transfered to Silos.) Quantity of Raw materials by lot consumed.) Quantity of Raw materials non lot consumed
WM
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Implementation Design - Components
SYNAPSIS
• PI 3.2 Real time data historian, Batch Monitor and totalizations
• PS-RLINK PI system gateway to SAP R/3 PP-PI module
• PI-ProcessBook 2.0 Graphical representations and PIBatchView management of:
- Process data (PI) - Process Order (SAP Recipe)
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Implementation Design - Infrastructure
Polimeri WAN
Milan Head Office
Public Network
PI ProcessBook
PI ProcessBook
PI ProcessBook
PI Home node
PLANT SUITERLINK
DCS
SITE
SAP
SYNAPSIS
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Implementation Design - Model
SYNAPSIS
• Process Order Stored in Plant Suite Managed as a PI Batch Unitwith its own PI Tags
• Phase Each phase is a PI Batch Unit with its own PI Tags
• Material(s) Each material is a PI Tag
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Implementation Design - Data Sources
SYNAPSIS
Different data sources had to be used:
• DCS Input Real time data collected by standard PI interfaces.
• Manual entry Manul data to be entered by operator
• Unmeasured (Standard) Data to be computed on
the base of the recipe standard
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Implementation Design - Data Sources solution
SYNAPSIS
Different solutions have been implemented:
• DCS Input Standard PI features such as : - Performance Equation
- Totalizer
• Manual entry A specific ProcessBook display has been
developed using VBA
• Unmeasured (Standard) A specific program has
been developed and integrated using PS-RLINK standard features
RESULT: ALL IS IN PI SYSTEM
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-> Start and End Phase -> Material Quantity Consumed/ Produced -> Phase ID -> Recipe ID-> Phase confirmation Type (Partial/Finished)
PRIOLO PLANT DETAIL
Reactor
BlenderB
BlenderC
BlenderD
BlenderA
Silos
Priolo PlantReactor -> Duration Phase: ~ 4 hours -> By-product is moved to one Blender every phase confirmationBlender -> 4 Blenders -> Duration Phase: ~ 13 hours -> By-product is moved to ‘Silos’Silos -> Not a real phase: Material transfered to Silos
Priolo Units
Unit Information
SYNAPSIS
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RESOURCE AND PHASE - ONE PROCESS ORDER
MANY PHASES CONFIRMATIONS
TIME
ORDER
order_pi_statusorder_sap_recipe
0
1
CRID1
PHASE
phase_lot_numberL1 L2 L3 L4
phase_sap_statusStart Partial EndPartial Partial
phase_pi_statusStart EndEnd/Start End/Start End/Start
SYNAPSIS
phase_sap_recipeCRID1 CRID1 CRID1 CRID1 CRID1
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SYNAPSIS
PB Display - Overall view
Blenders Details
Reactor Details
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SYNAPSIS
PB Display - Reactor
Viewing Lots in Reactor
SAP Process Order Information
PLANT_SUITE
Process InformationP I
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SYNAPSIS
PB Display - Reactor
New Campaign Selection Window
Lot Details Window
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SYNAPSIS
PB Display - Blender
Process InformationP I
Moving Lot across Blender and Silo
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SYNAPSIS
PB Display - Silos
Viewing lots in Silo (Selected Process Order)
P I
SAP Process Order Selection
PLANT_SUITE
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Conclusion
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PE Project Opera “First’s”
• SAP electronic connection to Italian banks
• use of SAP HR and TR modules
• third party facilitiy management of client server environment
• integration of information systems from DCS through RTDB to SAP business reporting systems
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Closing Observations
• SAP and RTDB are technology tools, that provide significant productivity improvement opportunities on their own, but are not the complete solution.
• The real breakthrough was the integration that came from committed and creative process sponsors and technologists who insisted on a seamless flow of information from the process unit to business managment.
• The result of direct hands on end-user involvment made certain that an integrated solution eliminated duplication of data input and aimed at reduced overall operating costs.
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