Polimeri Europa System Integration Project - Sigmafine · POLIMERI EUROPA AN ENICHEM ... RTDB SAP...

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1999 PI SYSTEM USERS’ CONFERENCE

1999 PI System Users’ Conference

Monterey, California

POLIMERI EUROPA AN ENICHEM | UNION CARBIDE VENTURE

SYNAPSIS

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Taking SAP to the Factory Floor

an

Italian Experience

Ing. Carlo Volpones, POLIMERI EUROPA

Sig. Roberto Spoladore, SYNAPSIS

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Agenda

• Company Profile

• Program Opera

• Management and Technology Challenge

• Company Key Decisions

• Implementation Partners

• Manufacturing Implementation

• Implementation Design

• 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 1998

• Sales Revenue 1.6 Billion USD

• Total Capacity 1,600 Polyethylene kty

700 Ethylene kty

• Employees 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

• Technology UCC Gas Phase

• Total capacity 400 Polyethylene kty

• Production lines 2 lines

• Type of products LLDPE-HDPE

• Customer satisfaction High Level of Acceptance

• First company implementation of OSI PI3 RTDB system

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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 effectiveness 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

Italy France

Germany

Process Application Solution

SAP R/3 Standard vers. 3.1

FI EIS QM CO/CCA PS PM

TR HR WM AA SD SD SHP

IM MM PP-PI LC

Scientific Systems and

Niche Applications

RTDB

LIMS

SCM

Transportation

Executive

Business Infrastructure

Fulfill

Demand

Balance

Supply &

Demand

Create

Demand

Service

Customer

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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 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

Transport order

Production order

Factories

Stock

Local offices

Profit Center

Material

Warehouses Message/ Event Handler

Distribution Centers

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Definition of Operations Work Processes

HS&E HS&E Maintenance Maintenance Manufacturing Manufacturing

Sub Processes

• Plant line

schedules

• Production

• Quality Control

Sub Processes

• Plan & Schedule

Maintenance

Activities • Execute

Maintenance

Activites

• Maintenance

Engineering

Sub Processes

• Environmental Compliance

• Process Safety

•

Product Safety •

Personnel Safety

• Process Engineering

• Technology

Development

• Engineering

Sub Processes

Manufacturing Process Technology

and Engineering

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Implementation Partners

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Implementation Partners

(MGC)

Hewlett Packard Hardware and system software

OSI SOFTWARE (Synapsis )

RTDB

Ernst & Young Managing General Contractor

Polimeri Europa • Head office

• 7 plants

• many warehouses

(Synapsis)

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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 continuous and batch

operations.

• Finished product is packaged and sold to customers in

batches.

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Overall 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 automatically.

• Production Planning is compiled at headquarters with

detail execution at the plants.

• Plant operators have one and only one interface for data

input.

• Standard solution through the different DCS vendors.

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SAP Modules Utilized for the

Integrated 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 raw

material, 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 modeled 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 campaigns: production quantities

calculated of materials consumed and resources utilized for

each finished product.

• Economic analysis (cost summaries, and efficiency 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 (cont.)

• Advancement of production interfaced with RTDB.

• Available to Promise (ATP) updated in real time with planned

transfers relative to production orders.

• Raw material to finished 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 FI SAP MM

Production

Campaign

Lot Traceability

Reports

Production

Campaign

Cost Reports

Finished Product lot to test transfers

Consumption (actual and std.) raw material (by lot and non)

Phase

Closure

Information from RTDB :

.) Finished lot Product to test.

.) Quantity of Finished product transferred to Silos

.) Quantity of Raw materials by lot consumed

.) Quantity of Raw materials non lot consumed

WM

QM

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Implementation

Design

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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 SUITE

RLINK

DCS

SITE

SAP

SYNAPSIS

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Implementation Design - Model

SYNAPSIS

• Process Order Stored in Plant Suite Managed as a PI Batch Unit

with 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 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

AS A 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 Plant Reactor

-> Duration Phase: ~ 4 hours

-> By-product is moved to one Blender

every phase confirmation

Blender

-> 4 Blenders

-> Duration Phase: ~ 13 hours

-> By-product is moved to ‘Silos’

Silos

-> Not a real phase:

Material transferred to Silos

Priolo Units

Unit Information

SYNAPSIS

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RESOURCE AND PHASE - ONE PROCESS ORDER

MANY PHASES CONFIRMATIONS

TIME

ORDER

order_pi_status

order_sap_recipe

0

1

CRID1

PHASE

phase_lot_number L1 L2 L3 L4

phase_sap_status Start Partial End Partial Partial

phase_pi_status Start End End/Start End/Start End/Start

SYNAPSIS

phase_sap_recipe CRID1 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 Information

P 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 Information

P 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 facility management of client server

environment.

• Integration of information systems from DCS through

PI3 to SAP business reporting systems.

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Closing Observations

• SAP and PI3 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 management.

• 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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Polimeri Europa System Integration Project - Sigmafine · POLIMERI EUROPA AN ENICHEM ... RTDB SAP...

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