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


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


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


Main Office Block

Machining Facilities

Blade ManufactureBalancing Facilities

Generator Repair

C.A. Parsons Works


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


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


Large complex parts eg Casings and Rotors


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


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


Customers – Power Station owners

SPG History

SPG at a Glance

SPG Capabilities

SPG Customers & References

Power GenerationMay, 02 Slide 12

ERP System background


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 !


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


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


Sample Avante GUI screen


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


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


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


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


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


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


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


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


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


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


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


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 !?!??


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


The End

Any

Questions

power generation may, 02 slide 1 siemens power generation – phil scotson

Documents

conclusion slide

groups siemens

agencies power automation

power plants expertise

nuclear power station

mw turbine

turbine driven generator

condensing turbine