Power Generation May, 02 Slide 1 SIEMENS POWER GENERATION – Phil Scotson.
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Transcript of Power Generation May, 02 Slide 1 SIEMENS POWER GENERATION – Phil Scotson.
Power GenerationMay, 02 Slide 1
SIEMENS POWER GENERATION – Phil Scotson
Power GenerationJune 04 Slide 2
Presentation structure
Company background
ERP system background
Scope of use – defining the interfaces
Interfaces in detail
Conclusion
Power GenerationJune 04 Slide 3
Stand: 01.01.2001
Managing Board
Regional organization: Regional Offices; Regional Companies, Representative Offices, agencies
Power
Automation and Control
Automation and Drives (A&D)
Industrial Solutions- and Services (I&S)
Siemens Dematic AG (SD)
Siemens BuildingTechnologies AG (SBT)
Information andCommunication Networks (ICN)
Information andCommunication
Information andCommunication Mobile (ICM)
Siemens Business ServicesGmbH & Co. OHG (SBS)
Transportation Systems (TS)
Transportation
Siemens VDO Automotive AG (SV)
Osram GmbH
Lighting
Siemens Financial Services GmbH(SFS)
Finance and Real Estate
Medical Solutions (Med)
Medical
Power Generation (PG)
Power Transmission andDistribution (PTD)
Siemens Real Estate (SRE)
The Organizational Structure of SiemensBusiness Segments and Groups
Siemens at a Glance
Siemens PG Profile
Siemens PG Key Figures
Power GenerationJune 04 Slide 4
Siemens Power Generation:
A strong number 2 ranking in the global power plant market
Concentration on fossil-fuelled power generation technology, components, systems and power plants
Expertise in power plant and system services
Long-term operation and maintenance (O&M) agreements
Leading vendor of industrial applications
Successful integration of the fossil division of Westinghouse
Innovation and technical advancement
Power Generation
Portrait
Siemens at a Glance
Siemens PG Profile
Siemens PG Key Figures
Power GenerationJune 04 Slide 5
Main Office Block
Machining Facilities
Blade ManufactureBalancing Facilities
Generator Repair
C.A. Parsons Works
Power GenerationJune 04 Slide 6
CA Parsons Works - Facts and Figures
Circa 700 personnel
Site covers 170,000 m2
OEM Status for over 60,000 MW of plant
Fleet in over 32 Countries Worldwide
Over 100 years on the site
$ Turnover in excess of $100 million
Power GenerationJune 04 Slide 7
First Turbine Driven Ship1897
First Turbine Driven Generator1884
First 50 MW Turbine1922
First Industrial GT in UK1945
First Nuclear Power Station1953
First 500 MW Cross CompoundTurbine -1961
First 660 MW Turbine in UK1986
First Condensing Turbine1891
Sir Charles ParsonsFounded Parsons Works 1889
Power GenerationJune 04 Slide 8
Large complex parts eg Casings and Rotors
Power GenerationJune 04 Slide 9
Heavy Machining
80 CNC Machine Tools170,000M2 Covered areaCranage up to 300 tonnesOver 12,000 Man Years of ExperienceAll Major design types worked on
Generator Rotors
Turbine Assembly
Blade Manufacture
Production Facilities
Power GenerationJune 04 Slide 10
On-Site Maintenance Services
Site ManagementCommissioningDynamic BalancingIn-Situ MachiningNDT
Technical and Operational Support
Design ConsultancyMetallurgical ServicesTechnical Advice
Spares and Repairs
Outage RelatedStrategicBreakdown
Retrofits
Efficiency ImprovementsLife Extension and IntegrityMaintainability ImprovementsLatest Technology
Services to the Power Industry
Power GenerationJune 04 Slide 11
Customers – Power Station owners
SPG History
SPG at a Glance
SPG Capabilities
SPG Customers & References
Power GenerationMay, 02 Slide 12
ERP System background
Power GenerationJune 04 Slide 13
ERP Implementation plan
Steering group, Reps from all business functional areas
Evaluation process
Change business processes
Big bang implementation
Best fit for business - at the time !
Power GenerationJune 04 Slide 14
ERP Project Aims - Integrated Business System
Improve planning systemsBetter ability to accurately predict, therefore to manage the business
Question and change our working practices as required Single / correct way of operation (only one version of the truth)
Consistency and complete dataNo islands of informationReduce multiple data entry / increased reuse of dataSingle user interface (expert in 1 system)
Get off obsolete / unmaintained databases & hardware To keep our Business Systems up to date with evolving technology
GUI, potential for E-business
Power GenerationJune 04 Slide 15
Avante ERP Technical details
Avante from software company Epicor
U2 – Unidata PICK database - multivalue, transactional based
120 concurrent user licence.
Multi processor server, 4 Pentium4, 2Gb memory, RAID discs
Live account = 1 000 MBytes
Power GenerationJune 04 Slide 16
Sample Avante GUI screen
Power GenerationJune 04 Slide 17
The extent of Avanté
Custom erM anagem ent
Custom erO rder
B .O .M .&
Draw ing
EngineeredItem s
Standardrouting
StandardO perations
EnquiryM anpow erEstim ate
T enderEstim ates
Q ualityRequirem ents
Custom erInspectiions
StockRequirem ents
PurchaseRequirem ents
StockContro l
PurchaseO rders
G .R .N . &Q .C .S.
T oolingCNC
Program m es
O perationRoutings
Shop O rder
M anufacturingLaunch
M anufacturingDocum entation
Shop O rderProgress
Dispatch
F inance
SchedulerContractUpdate
Packaging
T ransport
M anuf.W orkcentres
M aintenance
M achines
Calenders
Departm ents
Shift Patterns
M en
T im e &Attendence
Skills
InvoicingW IPPaym entsPro ject Cost Contro l
M anufacturingERP Im plem entation M ap
Logistics F inance
Procurem ent
Q uality
Engineering
Contract m anagem ent
G eneric BO MStructures
G enericItem s
RepairInstruction
Site
Site
W ages
Power GenerationJune 04 Slide 18
Scope of ERP use – therefore integrated
Quotations & Sales Order acknowledgements Order BOM configurations
Material Control Purchasing, MRP & buy to order Quality Control, Stock control, Tool mgt
Manufacturing Work order routings, progress status Lead time Planning, + feeding details for finite scheduling Change control & Locking
Project / order management Costing – standard, budget, actual hours & costs
Shipping / despatch control
Financial control Supplier invoices, payments, cash mgt Sales invoices
All official company external documents
Power GenerationJune 04 Slide 19
Out of scope – therefore interfaces to other systems
Engineering – to & from in-house PDM system, future – global PDM
SFDC – to & from in-house timelines, clock card system
Site Operations – to & from in-house system
Payroll / personnel – to & from
APS – Advanced Planning System – finite scheduling module
NB. Non to customers / suppliers via Ebiz
Power GenerationJune 04 Slide 20
Why out of scope ?
Forced Working within a Global company Helping implementation, practicalities
By design, optimum use Better ‘external’ software solution eg APS External process eg payroll
Power GenerationJune 04 Slide 21
Engineering PDM System interface
In-house PDM simulates future global Siemens solution
To Engineering Order MBOM configurations Generic components, required dates & priority order Changes to dates, emerging extent of supply
From Engineering Order EBOM configurations Specific items (parts) with all associated attributes Changes to items & drawings
Polling for data, every minute
Token codes dictate process
Power GenerationJune 04 Slide 22
Shop Floor Data Capture interface
To SFDC Work order operation routings – what to make, when, on what machines Changes
From SFDC Progress status Timelines, hours taken Clock cards, overtime & shifts
Polling for data, every minute
Token codes dictate process
Batch ASCII files manually invoked, schedule time
Power GenerationJune 04 Slide 23
Other interfaces
Site Operations To Site Ops - Work order routings – for validation @ source From Site Ops - Timelines, clock cards
Payroll To Payroll - Overtime & Shifts From Payroll - Full payroll costs into Financial journals
Personnel From Personnel - New starters, leavers, movements
APS – Manufacturing Finite scheduling key resources To APS – outstanding work, estimated hours, earliest start dates From APS – priority work lists, expected completion dates
Power GenerationJune 04 Slide 24
How the interfaces work
Polling, auto running 24x7 Every minute searching for a file on network drive First section of each line is a token code Each code calls specific interface process or simulates a manual menu
process
Batch file updates, scheduled day & time or manually control when run Each line predefined format, usually csv Error files log any problems
Simulating manual processes, same validations as for users
Populate database records directly
Archive copies held to enable re-runs
Power GenerationJune 04 Slide 25
Positive aspects
Allows split between global & local business systems Eg global PDM Engineering & local ERP
Allows phased implementations, avoids too much of a big bang Functionality not yet available, training users Eg SFDC
Out of scope of the ERP system Better specialist software used for specific tasks Eg APS finite scheduling & its what-if scenarios
Remote users, not on network Eg Site Operations @ Power Stations
Power GenerationJune 04 Slide 26
Negative aspects
Cost of developing Specification, writing, testing all envisaged permutations
Delays on implementation time schedules
Not moving off legacy systems, not a clean break
Extra links in information chains, PC – Unix, debugging
Ongoing maintenance costs External bespoke software support Internal system support
Power GenerationJune 04 Slide 27
Negative example - Avante / PDM interface
Not originally envisaged
Global initiative, optimistic time scales for availability
Costs (man hours) Internal – defining functional specification, testing External – detail system spec, writing software
100 k but capped !
Delay whole ERP implementation project plan - 8 months Originally planned (optimistically) 9 months (Oct 99 – July 00) Actual project time 17 months – live in Mar 01
Power GenerationJune 04 Slide 28
Future interfaces - XML
Standardised approach
Predefined, standard format of files
Simulates manual menu screen process
Mapping of XML fields to process fields (screen variables)
Designed for Ebiz but wider application
Off the shelf interface solutions !?!??
Power GenerationJune 04 Slide 29
Conclusion
Overview of the Avante ERP system at SPG Large traditional manufacturing industry, global organisation Other systems - existing, legacy, global, external
Reasons for interfaces to & from ERP
Details on the interfaces
Positive aspects
Negative aspects
But usually critical, KIS - Keep It Simple
Power GenerationJune 04 Slide 30
The End
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