1 manufacturing systems integration at. 2 ma hanna yesterday headquartered in cleveland, ohio...
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Manufacturing Systems
Integration at
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MA Hanna YesterdayMA Hanna Yesterday Headquartered in Cleveland, Ohio
Employs 7,000 people worldwide $2.3 Billion in Sales - 1999
Resin Distribution $ 460 million
Rubber Compounding $ 529 million
Color Compounding $ 483 million
Plastics Compounding $ 437 million
Shapes $ 391 million
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Geon YesterdayGeon Yesterday Headquartered in Avon Lake, Ohio
Employs 3,100 people worldwide World’s largest producer of vinyl (PVC)
compounds $ 820 Million
North America’s largest producer of dispersion resins & formulators $ 235 million
Engineered Films $ 215 million
Joint Venture with OxyChem (OxyVinyls) & various joint ventures worldwide
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StrategyStrategyStrategyStrategy
PPoollyymmeerrss
AAddddiittiivveess
Appliances &Business Equipment
PackagingPackaging
ConsumerConsumerProductsProducts
CCoonnssuummeerrss
Communications/Electronics
DDeessiiggnneerr//AAsssseemmbblleerr
CCOOMMPPOOUUNNDDEERRSS
PPRROOCCEESSSSOORRSS
Service & Service & DistributionDistribution
Building Materials
Automotive
Packaging
Consumer Products
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Manufacturing Integration HistoryManual Plant pilot
•Scope & Design•User Views
Automated Plant Project•Scope & Design, Data Views
Lessons & ExperiencesQuestions?
Manufacturing Systems
Integration at
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This initiative was focused in large part on our compound manufacturing assets and product line.
Su
pp
lier(
s)
Cu
stom
er(s)
Sell-Service Design-Make Source Logistics-Delivery Close Sale
Receive Payment
Order Fulfillment
ProcurementManufacturingOrder Processing
Planning
In 1988, we began our Computer Integrated Enterprise vision by attempting to simplify,
automate and integrate our internal processes
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Corporate
Process Model(SCADA)
Manufacturing Execution
System (MES) -PROCESS/1Inventory
Management
Procurement
Planning
Forecasting/PlanningSystem
Order EntrySystem
FinancialSystem
FG / ShippingSystem
Raw MaterialInventorySystem
Run TrackingProcess Control
GENERAL STORE
Distribution
Plant
Line
SID
LIMSCHAMPS
NTNT
Geon’s Computing Environment
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High Level Information Flow
PREPARE FOR PRODUCTION
RUNS
PREPARE FOR PRODUCTION
RUNS
EXECUTE PRODUCTION
RUNS
EXECUTE PRODUCTION
RUNS
ANALYZE PRODUCTION
RESULTS
ANALYZE PRODUCTION
RESULTS
INPUTS KEY FUNCTIONS
OUTPUTS/ INPUTS
KEY FUNCTIONS
OUTPUTS/ INPUTS
KEY FUNCTIONS
OUTPUTS
MATERIAL DELIVERIES
PRODUCTION SCHEDULE/
BOM
SPC/SQC ANALYSIS RESULTS
RECIPE ADJUSTMENTS
PREPARE LINE RECIPE PACKET
ORDER, RECEIVE, AND
BAR-CODE MATERIALS
SET UP SPC SPECS
LOT SPECIFIC RECIPE PACKET
SPC SPECS
BAR-CODED RAW
MATERIALS
PICK RAW MATERIALS FOR
3RD & 4TH FLOOR
MAKE-UP BULK, MASTER BATCH AND HAND-ADD
MATERIALS
EXECUTE, CONTROL, AND MONITOR RUN
TRACK ACTUAL RUN
PERFORMANCE
RUN HISTORY:
•PRODUCTION RUN AUDIT TRAIL
•MATERIAL USAGE
•FINISHED GOODS PRODUCTION
•RUN START/STOP TIMES
•DOWNTIME EVENTS
•SALVAGE
•PROCESS VARIABLES
MATERIAL PERFORMANCE VIEW/UPDATE
ANALYZE RUN PERFORMANCE
PERFORM SQC ANALYSIS
RUN PERFORMANCE
MEASURES
PRODUCTION RUN AUDIT
TRAIL
SPC/SQC ANALYSIS RESULTS
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The Manufacturing Systems Journey
EXECUTEPRODUCTION
RUNS
CONTINUOUSIMPROVEMENT
PREPAREPRODUCTION
RUNS
ANALYZEPRODUCTION
RUNS
INCREASE QUALITYAND CONSISTENCY
COMPETITIVECOSTS
CUSTOMERRESPONSIVENESS
SIMPLIFICATION
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A Manufacturing Pilot is recommended to close gaps between sites, leveraging best practices and information driven capabilities
Manufacturing Decision Support• standard decision support tools
• common measures across sites
• common basis for comparisons
• data warehouse at each plant (compound and specialty resin) and corporate
Data Acquisition
• standard data acquisition approach• standard data elements• standard data structure • Manual data capture where controller data
feeds unavailable
Line Recipe Management• LRM capability extended to plants where it
does not exist • PRM can be supported with more common
skills
CorporatePlant
SAP
MDS
OSI PI
MDEProcess Ctl
LRM/PRM
DW• EIS• MDS• Other
All Geon Sites
• EPM• P1
• DA• DH/DHE• SQC
Mfg. Systems Strategy Study
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Mfg. study revealed several things:
The Major drivers are Technical obsolescence No viable solution to offer non-legacy plants
There is no single piece of functionality that is driving the savings
Timing of the SAP 4.6 upgrade is critical to our plan of action
Mfg. Systems Strategy Study
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Manufacturing Integration HistoryManual Plant pilot
•Scope & Design•User Views
Automated Plant Project•Scope & Design•User Views
Lessons & ExperiencesQuestions?
Manufacturing Systems
Integration at
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CorporatePlant
SAP
MDS
OSI PI
MDEProcess Ctl
LRM/PRM
DW• EIS• MDS• Other
All Geon Sites
• EPM• P1
• DA• DH/DHE• SQC
OSI RLink Pilot
At Farmingdale PlantAt Farmingdale Plant
Prove OSI PI link to SAPProve OSI PI link to SAP
•Manual Data Manual Data entry to OSI PIentry to OSI PI
•Automatic interface Automatic interface to SAP via OSI RLinkto SAP via OSI RLink
•Ability to analyze Ability to analyze data in OSI PIdata in OSI PI
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BOXBOX To BulkTo Bulk
MASTER BATCH MATERIAL
BULK MATERIAL
HAND ADD AND
COLOR BLEND MATERIAL
Two distinct Orders
SAP Master Recipe Design
Order 1 Order 2
Each Order:
•one operation
•one phase
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Standard PSRLink Interface
for Informational Data
AMAT
AMATP01
APHASE
AORD
APHAR
SAP R/3
PP-PI
PSRLINK
PI
Process Instructions
Control Recipes
SAP PP-PI Process Instructions/Messages
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AORD - Order Data including start/finish date/time
APHASE - Phase Data including External Phases
AMAT - Material Allocation Info Raw Material consumption
AMATP01 - Material Allocation Info
Finished Goods production
APHAR - Phase Parameter Blender Batchsize
SAP PP-PI Process Instructions/Messages
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Standard PSRLink Interface
for Process Data Request
ACONS
APROD
APHCON
ACRST
SAP R/3
PP-PI
PSRLINK
PI
Process Instructions
Control Recipes
Process Messages
SAP PP-PI Process Instructions/Messages
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ACRST - Control Recipe status Start/Processed/Discarded
ACONS - Goods Issue Raw Material consumption (MAT_CONS)
APROD - Goods Receipt Finished Goods production (MAT_PROD)
APHCON - Time Ticket Info Confirmation Qty & Time
SAP PP-PI Process Instructions/Messages
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SAP Order Process Instructions
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SAP Order Process Instructions in RLink
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Material Tags (Batch & Qty)•Resin•Impact Modifier•Stabilizer•Pigment
X Resin1 250#
X ImpMod2 150#
X Stab3 100#
X Pigment4 50#
X Resin1 250#
X ImpMod2 150#
X Stab3 100#
X Pigment4 50#
X Resin1 230#
X ImpMod2 140#
X Stab3 110#
X Pigment5 60#
1st Conf.Resin1, 250ImpMod2, 150Stab3, 100Pigment4, 50
2nd Conf.Resin1, 480ImpMod2, 290Stab3, 210Pigment4, 50Pigment5, 60
Phase start Phase confirmation Phase confirmation
RLink Translation Method
Time
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Manufacturing Integration HistoryManual Plant pilot
•Scope & Design•User Views
Automated Plant Project•Scope & Design, Data Views
Lessons & ExperiencesQuestions?
Manufacturing Systems
Integration at
23
Starting Recipe & PhaseStarting Recipe & Phase
Process Orders are sorted byStart Date and mimic the ZSCH screen in SAP which
is still used to schedule production
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Blender Production ReportingBlender Production Reporting
Enter the correct Batch numbers for all the RM you used with a drop down!
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Blender Batch Process DataBlender Batch Process Data
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Compound Production ReportingCompound Production Reporting
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Compound Cont. Process DataCompound Cont. Process Data
You can quickly see process data trends right on the screen
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User Developed Custom AppsUser Developed Custom Apps
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User Developed Custom AppsUser Developed Custom Apps
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User Developed Custom AppsUser Developed Custom Apps
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Manufacturing Integration HistoryManual Plant pilot
•Scope & Design•User Views
Automated Plant Project•Scope & Design, Data Views
Lessons & ExperiencesQuestions?
Manufacturing Systems
Integration at
32
CorporatePlant
SAP
MDS
OSI PI
MDEProcess Ctl
LRM/PRM
DW• EIS• MDS• Other
All Geon Sites
• EPM• P1
• DA• DH/DHE• SQC
on Vaxon Vax
The Next Step
At a Legacy PlantAt a Legacy Plant
Prove No Process/1Prove No Process/1
•Automatic PCS Automatic PCS interface to OSI interface to OSI PI/RLinkPI/RLink
•Proven Auto Proven Auto interface to SAP via interface to SAP via OSI RLinkOSI RLink
•Ability to analyze Ability to analyze data in OSI PIdata in OSI PI
•Interface OSI PI/RLINK Interface OSI PI/RLINK with Vax LRM/PRMwith Vax LRM/PRM
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As-Is Process Model InterfacesAs-Is Process Model Interfaces
SAPSAP
LIMSLIMS
P1P1 PIPI
ProvoxProvox
ModelModel
A- PGLRM703 (.SCO,.COM)(Schedule Sequence)
A- PGLRM701 (BOM Information)
A- PGLRM702 (Campaign Information)
A- Vend_lot_val (Valid Vendor Check)
B- PGRTR701 (Consumption)
B- PGRTR710 / 702 (Production/Finished Goods Adjustment)
B- PGRTR706 (Grade Change: P1 & SAP)
B- PGRTR711 (Campaign Pending Close)
B- PGRTR704 (Campaign Close)
B- PGRTR720 (Downtime-Function in SAP)
B- PGPCM042 (Inventory Transfer)(.exe)
B- PGPCM040 (Inventory Transfer:part of 042)
B- PGRTR702 (Production: Part of PGRTR710)
B- PGRTR800 (Vendor Lot Modification: Consumption)
B- PGRTR716 (MB/CB Reconciliation)A B
C
D
C- PGRTR703 (Submitted by PRM at Campaign Completion)
C- PGLIM703 (LIMS Campaign Close)
C- PGLIM702 (Sends PMU’s to LIMS)
D- PGTR705 (LIMS Grading)
Process Control
PGRTR706 (R-Mail Grade Change)
Question:
*PGPCM098 (Global Section Backup-BMAT)
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New Process Model/RLink/SAP InterfacesNew Process Model/RLink/SAP Interfaces
SAPSAP
LIMSLIMS
PIPI
ProvoxProvox
ModelModel
F/A-(Order DownLoad)
F/A- PGLRM701 (BOM Information)
F/A- PGLRM702 (Campaign Information)
B/E- PGRTR701 (Consumption)
B/E- PGRTR704 (Campaign Finish)
B/E- PGRTR710 (Production)
B/I- PGRTR716-(Consumption: 4hr. delay)
B/I -PGRTR720 (Line events)
B/I- PGRTR706 (Unsolicited: Initial Grade Change: SAP)
B/I- PGRTR702 (Finished Goods Adjustment) B- PGPCM042 (Inventory Transfer-SAP/-Rmail to SAP)
F/A- PGLRM703 (Schedule Sequence/Order Date Change (TBD))
E = Solicited
I = Unsolicited
AC
D
These Are Model and LIMS Specific:
C- PGRTR703 (Submitted by PRM at Campaign Completion)
C- PGLIM703 (LIMS Campaign Close)
C- PGLIM702 (Sends PMU’s to LIMS)
D- PGTR705 (LIMS Grading)
PGPCM098 (Global Section Backup:Model Specific)
Process Control
E/IF
Existing ProgramsExisting Programs
Rlink ServerRlink Server
SQLVB
B/I
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BOXBOX To BulkTo Bulk
MASTER BATCH MATERIAL
BULK MATERIAL
HAND ADD AND
COLOR BLEND MATERIAL
Mixer
Phase
Extrusion
Phase
Packaging
Phase
Each Order has One Operation
SAP Master Recipe Design
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SAP Order Operations & Phases
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Standard PSRLink Interface
for Informational Data
AMAT
AMATP01
APHASE
AORD
SAP R/3
PP-PI
PSRLINK
PI
Process Instructions
Control Recipes
SAP PP-PI Process Instructions/Messages
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AORD - Order Data including start/finish date/time, PolyOne
ProdVers
APHASE - Phase Data including External Phases
AMAT - Material Allocation Info Raw Material consumption
AMATP01 - Material Allocation Info
Finished Goods production
SAP PP-PI Process Instructions/Messages
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Standard PSRLink Interface
for Process Data Request
ACONS
APROD
APHCON
ACRST
SAP R/3
PP-PI
PSRLINK
PI
Process Instructions
Control Recipes
Process Messages
SAP PP-PI Process Instructions/Messages
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ACRST - Control Recipe status Start/Processed/Discarded
ACONS - Goods Issue Raw Material consumption (MAT_CONS)
APROD - Goods Receipt Finished Goods production (MAT_PROD)
APHCON - Time Ticket Info Confirmation Qty & Time
SAP PP-PI Process Instructions/Messages
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SAP Order Process Instructions
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SAP Order Process Instr Characteristics
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SAP Order Process Instructions in RLink
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SAP Order Bill of Materials in RLink
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Tags RecipeMat’lBatchQty
X Rcp1 Resin Resin1 250#
X Rcp1 ImpMod ImpMod2 150#
X Rcp1 Stab Stab3 100#
X Rcp1 Pigment Pigment4 50#
X Rcp1 Resin Resin1 250#
X Rcp1 ImpMod ImpMod2 150#
X Rcp1 Stab Stab3 100#
X Rcp1 Pigment Pigment4 50#
X Rcp1 Resin Resin1 230#
X Rcp1 ImpMod ImpMod2 140#
X Rcp1 Stab Stab3 110#
X Rcp1 Pigment Pigment5 60#
1st Conf.Rcp1 Rcp1 Rcp1 Rcp1Resin ImpMod Stab PigmentResin1 ImpMod2 Stab3 Pigment4250 150 100 50
Phase start Phase confirmation Phase confirmation
Tags RecipeMat’lBatchQty
2nd Conf.Rcp1 Rcp1 Rcp1 Rcp1 Rcp1Resin ImpMod Stab Pigment PigmentResin1 ImpMod2 Stab3 Pigment4 Pigment5480 290 210 50 60
RLink Translation Method
Time
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RLink Interface data in PI
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RLink Interface data in PI
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RLink Interface data in PI
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Standard PSRLink Interface
for Unsolicited Process Data
ACONS
APROD
MATRANS1
MATRANS2
LINEVENT
SAP R/3
PP-PI
PSRLINK
PI
SAP PP-PI Process Instructions/Messages
Process Messages
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PI_CONS - Unsolicited CONS unplanned consumption (SAP_TRAN)
PI_PROD - Unsolicited PROD unplanned production (SAP_TRAN)
MATRANS1 - FG Grading Move from QI, then Batch ID change
MATRANS2 - Rework CONS Move from Blocked, then CONS
LINEVENT - Line Events Populates custom SAP table
SAP PP-PI Process Instructions/Messages
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RLink Interface data in PI
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RLink Alarming via PI tags
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Manufacturing Integration HistoryManual Plant pilot
•Scope & Design•User Views
Automated Plant Project•Scope & Design, Data Views
Lessons & ExperiencesQuestions?
Manufacturing Systems
Integration at
54
Manufacturing Integration HistoryManual Plant pilot
•Scope & Design•User Views
Automated Plant Project•Scope & Design, Data Views
Lessons & ExperiencesQuestions?
Manufacturing Systems
Integration at