direct materials pi and sap the eastman experience

EASTMAN1

Direct Materials

PI and SAP...The Eastman Experience

Eastman Chemical

OSI Software

Sharing ideas for a shared future......

EASTMAN2

Direct Materials

Process

Monitoring &

Control

Inventory

Management

Process

Control

Systems

Process Data

Historian

Lab

Instruments

Validation,

Control, Security,

Reporting, &

Service Functions

Lab

Management

(LIMS)

Run

Management

GloBIIS

Interface

Production

Planning

Storage/Distribution

Analysis

Qualification

Improvement

Manufacture

Production

Records

Scheduling

• 10 different systems• 7 development tools• 3 database technologies

• Similar in function• Diverse in details• Heavy on support• Hard to leverage• Data incoherence• Lack analysis tools• Aging technology

Why Consider a New System?

EASTMAN3

Direct MaterialsProject Scope

Implement an enterprise-wide integrated

manufacturing information system

Standardize on “best practices” and drive system

requirements through business process improvement

efforts

Deploy in 23 manufacturing sites worldwide

United States SingaporeArgentina WalesThe Netherlands CandaSpain Hong KongEnglandMalaysiaMexico

EASTMAN4

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Common

User

View

R/3

Planning

Schedule

Initiate

Prod.

Records

Inv. Mgmt.

Ship

DWH

Process/

Product

Knowledge

Mgmt.

Summary

Bus. Intel.

Dec.

Supp.

PIMS

Process

Control

Process

Conditions

Lab Inst.

LIMS

Architecture

EASTMAN5

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SAPR/2

MIS

DCS

“As-Is”

SAPR/3

DCS

ERP

PDH

DWH

LIMS

“To-Be”

MESA

SAP R/3

Impact on Programs

EASTMAN6

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PI/SAP Interfaces

Johnette McDanielPrincipal Systems AnalystInformation TechnologyLongview, Texas

EASTMAN7

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Pi Gateway to SAP

Eastman View

Interface Options

User View

Questions

PSRLink Overview

EASTMAN8

Direct Materials

OSI SOFTWARE

PI System Gateway to SAP R/3

Messages Recipe SP 88 Model

•Tag Mapping

•Material Mapping

•Instruction Translation

•Assign a Procedure

Request Handling

Action Results(wait until complete)

PSRLINK

Reply

Batch Execution

System (optional)

PI Batch (optional)

PI System

SAP

Man. Messages

EASTMAN9

Direct Materials

Pi Gateway to SAP

Eastman View

Interface Options

User View

Questions

PSRLink Overview

EASTMAN10

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Plant Suite Server Integration at Eastman Chemical Co. (LAR)

MM PM

SD

PP-PI

QM

SAP R/3 Applications

RFC’S, BAPI

(Remote Function Calls)

SAPAutomation Server

OLE

NT Servers

SAPGUI

Plant Suite Server

MicrosoftSQLServer

PI 3 Tools

Desktop Applications

ProcessBook

PIMS Apps

PI-SPC Client

PI-Batch Client

(Business API)

PSRLINK

PI Server

Alarm Watchdog

Manual Logger

Datalink Excel

Add-in

PSRLINK Client

EASTMAN11

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Pi Gateway to SAP

Eastman View

Interface Options

User View

Questions

PSRLink Overview

EASTMAN12

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Interface Options

Standard PI-PCS Interface

SAP to PI-Tag Value Updates

Material Movement Interface

EASTMAN13

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Interface Options

Standard PI-PCS Interface

– Start/Stop Control Recipes

– Start/Stop Phases

– Report Production

EASTMAN14

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SAP R/3

PP-PI

PSRLINK

PI

PI-SAP Automated Interface to PP-PI

Process

Instructions

Control Recipes

Process Messages

EASTMAN15

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Interface Options

SAP to PI-Tag Value Updates

– Eastman Customization

– Silo Blending Lab Values from

SAP to PI

– PSRLink System Management

Alarming

EASTMAN16

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SAP R/3

PP-PI

PSRLINK

PI

PI-SAP Automated Interface to PP-PI

Process

Messages

OSI_COMM

Messages

EASTMAN17

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Interface Options

Material Movement Interface

– Eastman driven enhancement

provided by OSI

– Unsolicited Messages sent from

PI to SAP

EASTMAN18

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SAP R/3

PP-PI

PSRLINK

PI

PI-SAP Automated Interface to PP-PI

Unsolicited

Process Messages

EASTMAN19

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Pi Gateway to SAP

Eastman View

Interface Options

User View

Questions

PSRLink Overview

EASTMAN20

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Plot-0

BA:CONC.1

BA:LEVEL.120

0

50

6.57430

13.20236

BA:CONC.1

BA:LEVEL.1

BA:PHASE.1Phase3

Shift Production Report

Production

Tags Se rve r 6/15/94 0:00 6/15/94 8:00 6/15/94 16:00

Report Parameters le:f440 tiglon 323.95 308.43 112.53

Date: 15-Jun-94 cd:f144 tiglon 681.19 928.18 1069.80

Mode: stdev le:f440 tiglon 323.95 308.43 112.53

cd:f144 tiglon 681.19 928.18 1069.80

0

500

1000

1500

Server 6/15/94

0:00

6/15/94

8:00

6/15/94

16:00

le:f440

cd:f144

le:f440

cd:f144

Private Sub BAphase1_NewValue()

If Baphase1.value = “Equipment Alarm” then

MAPISession1.SignOn

MAPImessage1.AddressLabel = "MaintenanceSupervisor"

MAPImessage1.AttachementName = "\PIAlarmReport.xls"

MAPImessage1.Send

End If

End Sub

VBA Scripting in ProcessBook

EASTMAN21

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Batch Production Reporting PB

PSRLink System Management PB

PSRLink Interface ProcessBooks in LAR

EASTMAN22

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Batch Production Reporting PB

PSRLink System Management PB

PSRLink Interface ProcessBooks in LAR

EASTMAN23

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Batch Production Reporting ProcessBook

EASTMAN24

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Batch Production Reporting PB

– Start/Stop Control Recipes

PSRLink Interface ProcessBooks in LAR

EASTMAN25

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Start / Stop Control Recipes

EASTMAN26

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Batch Production Reporting PB

– Start/Stop Control Recipes

– Start/Stop Mix Tank Batches

PSRLink Interface ProcessBooks in LAR

EASTMAN27

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Start / Stop Mix Tank Batches

EASTMAN28

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Batch Production Reporting PB

– Start/Stop Control Recipes

– Start/Stop Mix Tank Batches

– Start/Stop Batches and Report

Production

PSRLink Interface ProcessBooks in LAR

EASTMAN29

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Start / Stop Batches and Report Production

EASTMAN30

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Batch Production Reporting PB

– Start/Stop Control Recipes

– Start/Stop Mix Tank Batches

– Start/Stop Batches and Report

Production

– Create Batch Reports using Datalink

to Excel

PSRLink Interface ProcessBooks in LAR

EASTMAN31

Direct Materials

Batch Reports from Datalink to Excel

EASTMAN32

Direct Materials

Batch Production Reporting PB

PSRLink System Management PB

PSRLink Interface ProcessBooks in LAR

EASTMAN33

Direct MaterialsPSRLINK System Management ProcessBook

EASTMAN34

Direct Materials

PSRLink System Management PB

– PSRLink Applications

PSRLink Interface ProcessBooks in LAR

EASTMAN35

Direct Materials

Error Log Review

EASTMAN36

Direct Materials

PSRGUI

EASTMAN37

Direct Materials

EASTMAN38

Direct Materials

Configuration

EASTMAN39

Direct Materials

Access View of SQL Server Tables

EASTMAN40

Direct Materials

PSRLink System Management PB

– PSRLink Applications

– SAP Links

PSRLink Interface ProcessBooks in LAR

EASTMAN41

Direct Materials

EASTMAN42

Direct Materials

CO53 - Display Control Recipe Monitor

EASTMAN43

Direct Materials

CO54 - View Process Message Monitor

EASTMAN44

Direct Materials

View Gateway Monitor

EASTMAN45

Direct Materials

PSRLink System Management PB

– PSRLink Applications

– SAP Links

– Debugging Documentation

PSRLink Interface ProcessBooks in LAR

EASTMAN46

Direct Materials

EASTMAN47

Direct Materials

EASTMAN48

Direct Materials

PSRLink System Management PB

– PSRLink Applications

– SAP Links

– Debugging Documentation

– Problem Alarms

PSRLink Interface ProcessBooks in LAR

EASTMAN49

Direct Materials

EASTMAN50

Direct Materials

PSRLink System Management PB

– PSRLink Applications

– SAP Links

– Debugging Documentation

– Problem Alarms

– PSRLink Program Status

PSRLink Interface ProcessBooks in LAR

EASTMAN51

Direct Materials

EASTMAN52

Direct Materials

Pi Gateway to SAP

Eastman View

Interface Options

User View

What we have learned

PSRLink Overview

EASTMAN53

Direct Materials

Manufacturing Enterprise Systems Alignment

Questions & Discussion...

Sharing ideas for a shared future.....