polimeri europa system integration project - sigmafine · polimeri europa an enichem ... rtdb sap...
TRANSCRIPT
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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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1999 PI SYSTEM USERS’ CONFERENCE
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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