Bridging the gap towards the Digital Factory@ Puratos Group

© 2011, Puratos NVALL RIGHTS RESERVED.

Agenda

• Introduction• BRIDGE project: drivers• Project Preparation• Project Execution• Future Planning• Lessons learnt• Summary

ChocolatePatisserieBakery

Facts & Figures

Products and services available in more than countriesSubsidiaries in countries

production units in countriesemployees in the world

of the production is done in production units in Belgium

10063

42 560053

27 % 5

Groot -Bijgaarden Lummen Erembodegem Andenne Saint-Vith

Evolution of the annual turnover (in million €)

28/05/2013, Page 5

€ 828,9€ 883,2

€ 942,2 € 993,2 € 957,8

€ 1.090,0

€ 1.212,0€1.302,0

0,0

200,0

400,0

600,0

800,0

1.000,0

1.200,0

1.400,0

2005 2006 2007 2008 2009 2010 2011 2012

Challenge to manage this growth in production(Double the annual turnover in the period of 2010-2018)

• Add features which do not fit in ERP or SCADA

• Re-design the process and information flow

• Handle increasing data exchange from ERP till SCADA

• Handle higher flexibility in production

Challenge to manage this growth in production(Double the annual turnover in the period of 2010-2018)

• Add features which do not fit in ERP or SCADA

• Re-design the process and information flow

• Handle increasing data exchange from ERP till SCADA

• Handle higher flexibility in production

Urgent need for IT Automation

Main Drivers

Streamlined

Production

Quality

Data Products

Increased

Visibility (T&T)

Standardized

Open Platform

ReducedCost Of Non-

Quality

Project preparation

• 2009 – Approval project – Selection of pre-study partner out of 4 possible

partners• 2010

– Quick site surveys to define the needs• Interviews of all production related people on Belgian Sites• Verify results in some foreign sites

– Market Analysis:• Evaluation of 3 different systems

(Only MES suppliers with a world-wide support were selected)

– Product vendor selection

Project Execution

• 2011– Definition of template

• Define split MES / SAP functionalities• MES follows the SAP structure

– Setup of Bridge template• Main structure• Focus on functionalities which are needed at SAP start-up

– Setup interface MES-SAP– Different test-phases

• MES functionalities separated• Integrated SAP/MES tests

– Master-data setup

Project Execution

• 2012– Jan 1st : start-up Lummen

• Big-bang (SAP and MES)• Start support mode• But still development phase for other sites

– Feb 1st : start-up Andenne, St-Vith and GB part 1 • Need to have start-up teams on 3 different sites

– Apr 1st : start-up Erembodegem• First in-depth control-layer integration

– Jun 1st : start-up Groot-Bijgaarden• Biggest site• Huge masterdata and amount of batches• Start-up of detailed scheduler APO

Project Execution

• SAP and MES: same start-up date– Big challenge

• Almost all resources have to work on both projects while running the daily business.

• A lot of possible technical solutions• A lot of different opinions

– Need for close cooperation between both teams– Planning SAP roll-out is quite impossible to change

Very strict deadlinesAll Belgian sites are one juridical entity.

‘Obliged’ to switch over to SAP in the same yearWe wanted to avoid the start-up of SAP during our peak season

– Advantage: only one change for all people.

Project Execution: the result

• Principle scheme architectureGroot -Bijgaarden

Lummen Erembodegem

Andenne / Saint-Vith

Project Execution: the result

• Bridge Application Scaling

Groot -Bijgaarden Lummen

Erembodegem Andenne / Saint-Vith

• 16 MES servers• ± 100 MES-clients• > 100 ‘production lines’• > 100 printers connected• > 300 MES users• > 600 orders / day• > 2500 SKU• > 14000 messages/day

(between MES and SAP)

R3 / ECC 6.0

Load inLoad out

SIMATIC IT Industry LibraryPrimary Collection

SIMATIC IT Process Library OptionsCus

tom

erLi

brar

y

SIMATIC IT Enterprise Integration

Genealogy

SIMATIC BATCH 3rd Party PLC

3rd Party HMISIMATIC PCS7

SIMATIC IT Industry LibrarySecondary Collection

Tank Farm OEE

Recipe Mgt Production Order Handling Process Mgt Rework Mgt Recipe /

Routing MgtProduction

Order Handling

Material

Validation

Material Staging & Validation

Pallet & Labelling

SIMATIC IT Process Integration

Primary CollectionPlatform Achitecture

CREATION ORDER

Project execution: Integration recipe management

MASTER RECIPE

SITE RECIPE ORDER RECIPECREATION ORDER

RECIPE CREATION ORDER ORDER RECIPEEXTRA INFO

PLANT RECIPE CREATION ORDER ORDER RECIPEEXTRA INFO

CHANGES

CHANGES

SAP-MES interfaces

• Material management• Recipe management

• Bulk recipes• Order management• Transfers materials from warehouse to shopfloor• Order execution• Declaration productions• Bulk deliveries

Lessons learnt

Training and Involvement

Operators

Alignment of Cross EntitiesExpectation Level

Redesign Processes

Resistance to Change

Master-data is the KEY

to Success!

Implementation

Challenge

during Production Peak

Future evolution

• Extensions:– Extra functionalities

• Priority handling during project• New functionalities• Increase linking with PLC layer

– Historian / OEE– Automatic update of Simatic Batch recipes by SAP

• Roll-out– Pennsauken US

Summary: • Standardization in production over the different sites

• Production lines are now managed in a more uniform way• Open information system

• Web based platform• Reachable via any PC in Puratos and with VPN access

• Reduced data-input time• Not yet optimal, as first year is needed to organize and adjust all master-data• A lot of data is now transferred automatically between ERP and shopfloor• Automatic transfer

• Reduced cost of quality• We’re hopeful that this will still decrease once all master-data is correct and organization

is fully adapted to new ERP and MES system• Improved tracking & tracing

• All tracking and tracing is now done electronically• No need anymore to stop production during one day in Belcolade to count and adjust

stocks anymore direct increase of production capacity.• No second ERP program

• Big interface between two programs: both programs are a source for the other• Master-data on the right level

Summary

Streamlined

Production

Quality

Data Products

Increased

Visibility (T&T)

Standardized

Open Platform

Reduced Cost

Of Quality

Thank You