plm to power the enterprise - fusion lifecycle · $4.30 for australia, and $7.00 for northern...

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PLM to Power the Enterprise

- Jason Barnett, Advanced Solutions

- Mark Zeni, Ryan Markey, William Mitchell, First Solar

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Agenda

First Solar Fusion Set Up

System Configuration

Next Steps

First Solar Use Case

First Solar Introduction

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First Solar at a Glance

Driving innovation across entire value chain and plant solution

Cost competitive with conventional energy sources today

Partner of choice for leading utilities and global power buyers

Over 13.5GW sold worldwide and a 4GW contracted pipeline

Founded in 1999 and publicly traded on Nasdaq (FSLR)

Strongest financial stability & bankability in the industry

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World record 22.1% cell

History of Leadership Across Entire Solar Value Chain

Financed ~11B solar plants

Acquired EPC & project DEV

1999 … 2005 … 2007 2008 2009 2010 2011

State-of-the-art Operations Center

Proprietary plant controller

Industry leading tracker technology

World’s largest PV plants

Integrating into theglobal energy mix

1st global module recycling program

1st to break $1/watt cost barrier

1st to produce 1GW in single year

1999 2012 2013

World record 18.2% module

2014 2015

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Coal NuclearU.S. (NG) Japan (LNG) U.S. (NG)

Gas PeakingEU (NG) Japan (LNG) India

DieselAustralia EU

First Solar

Cost Competitive with Conventional Energy Sources Today

Sources: Coal and Nuclear: Bloomberg New Energy Finance LCOE Update: Q2 2013; Gas Combined Cycle, Gas Peaking, and Diesel: Lazard LCOE Sensitivity Analysis June 2013; First Solar: Internal data. (a) Does not include cost of carbon capture. (b) NG = natural gas. LNG = liquefied natural gas. Data assumes natural gas prices of $10 in Northern Europe and $18 in Japan (all in US$ per MMBTU). (c) Assumes diesel prices of $3.00 for India, $4.30 for Australia, and $7.00 for Northern Europe (all in US$ per gallon). Diesel assumes a high end capacity factor of 30% representing intermittent utilization and low end capacity factor of 95% representing base load utilization, O&M cost of $15 per KW/year, heat rate of 10,000 BTU/KWh and total capital costs of $500-$800 per KW of capacity.

a b b cGas Combined Cycle

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Business Problem

• PLM information is currently being managed using fragmented manual processes, Excel spreadsheets, SAP and SharePoint. Inefficiencies include:

— Lack of automation

— No single platform across First Solar

— No single “source of truth” for key product documents (drawings, revisions, BOM lists)

— Excessive manual effort required to track various stages of BOS products, changes, part numbers, etc. and keep SAP updated. Errors and rework occasionally resulted from these manual processes.

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Project Scope

• Replace SharePoint sites, Arena and Box.net systems with the new PLM system to support the following key business processes for BOS materials:

— Material Creation

— Material Change

— BOM Creation

— BOM Change

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Why Fusion Lifecycle?

• Highly configurable workflow tools

• Dynamic search tool and Full visibility to all revisions for Parts, Documents and Bill of Materials

• Easily navigate multi-level part assemblies to dive down to the subcomponents

• Impressive API capabilities for cloud-based platform

• Strong reporting tools

• Feasibility of SAP Integration Bulk import / Mass Update functionality

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Why Advanced Solutions?

• Highly skilled Industrial Engineering team to recommend best practices

• Decorated track record for quick and efficient Fusion Implementations

• Proven experience implementing Fusion with similar scale corporations

• Programmers capable of creating custom applications to fill the gaps between Fusion and external processes

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Early Wins

• End Users very excited about new system, widely adopted by various stakeholders within different functions

• Single source of Part Data established, previously more than three

• Workflow that includes entire process within a single system, customized individually to each stakeholder

• Allows users outside of workflow to view and download part data without possibility of disrupting workflow or corrupting part data

• Cut down New Part Creation and Part Change cycle times through streamlined workflow, eliminating steps outside of the critical path

• Established a standardized method to name, number, classify and categorize parts and documents

• Project success has empowered other areas within the company to analyze their processes and look for points of improvement

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Cost 2016 Savings 2016 Cost 2017 Savings 2017 Cost 2018 Savings 2018

Cost Savings Profit

Project Cost and Savings

$

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Part Data

• Part data that is managed by Fusion includes:

o Part Metadata

EX: Part Number, Description, Rev.,

o Documents

EX: Specifications, Technical Datasheets, Drawings, etc.

o Assemblies (Part BOMs)

EX: Tracker Bearing, AC Power Block, etc.

• Fusion is used to manage and create Project Bill of Materials with an “Interactive Parts Catalog”

o Enables Project Engineering and Management to work with the most recent part information

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Workspaces & Workflows

• Parts & Project BOMs

— Managed by:

– New Part Request

– Production Change Request

– New Part Clone Request

– Non-Engineering Change Request

– Obsolescence Change Request

• Documents are added & revision managed by the same workflows.

• Special ‘BOM Usage Type’ categories and Responsibility Matrix route the workflows.

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Responsibility Matrix

• Special workspace for workflow routing.

— Part Type assigned an Engineering Discipline.

— Engineering Discipline comprised of a team responsible for managing the records within a Part Type.

— Responsibility Matrix section included in Material Number records and related requests.

— Workflow Condition scripts check the user name and Group membership before sending notifications or allowing workflow Transitions.

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Responsibility Matrix: Condition Scripts

• Evaluates User Name, Group Membership & Responsibility Matrix values.

— Delegates may be assigned for some roles.

— Precondition script evaluates if user has permission and does not send Notification or display in Outstanding Work if the condition = false.

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Classification Manager

• The Classification Manager is used to standardize Material Classifications & Characteristics for alignment with SAP.

• Shared Characteristics stored in Phantom top-level classes for ease of management.

• Library script called from Action script to populate values.

• Tips:

— Get the sequence right the first time.

— System Name value can be edited for easier implementation with scripts.

— No Import or Reporting support.

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Custom API Desktop Applications

• Bulk Upload Utility

— Used to import large amounts of data to Grid Tab.

— Business Case: Extend Material Numbers & Cost to SAP Plants.

— Users populate CSV file and upload.

• Flatten Bill of Material Report

— Removes ‘Make’ and ‘Subcomponent’ items from a BOM regardless of location.

— Isolates only ‘Buy’ items that need to be purchased / have extended lead times.

• Deployed on VMware Horizon to minimize difficulty in deploying to many desktops.

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Next Steps

• Bi-Directional SAP Integration.

• Supplier Collaboration using ‘Third Party Licenses’.

• Extend Fusion Lifecycle to O&M and Manufacturing divisions.

• PDM Functionality via Autodesk Vault or Fusion PDM.

• Enhanced Reporting using Tableau.

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Project Finance Project Finance Deal of the Year 2011—Desert Sunlight 2012

Power Intelligence Best Renewables Deal—Desert Sunlight 2012

Solar Power Generation USA PV Project of the Year—Agua Caliente 2012

Malaysia Greentech Awards Gold Award—Manufacturing 2012

CLP Resources Safety Partner of the Year 2011 2012

Power Magazine Top Renewable Plant—Sarnia 2011

Power Magazine Top Renewable Plant—Copper Mountain Solar 1 2011

Renewable Energy World.com Solar Project of the Year 2010—Copper Mountain 2011

First Solar Track Record of Success: Awards and Recognition