dupont mfg integration to erp - american chemistry · pdf filedupont mfg integration to erp...

DuPont MFG Integration to ERPHistory, Description, and Value Capture – CISUG 9/10/07

Salvatore Grasso – Corporate Process Owner MFG/QM Carmen DeVito – Program Manager DuPont SAP

9/14/2007 DUPONT CONFIDENTIAL

2

Enterprise Operations Management

Common for allBusinesses

80%

Business Specific20%

“How do we take advantage of what our businesses have in common without losing of why we are different?”

“We identify, design, and build Common Configuration of

Best Practices and Business Specific

Competitive Advantage Practices.”


3

Initial standardization efforts were focused on business processes supported by SAP. How could this be expanded to include plant applications?

Business Planning & Logistics(ERP – eg SAP)

Level 4

ManufacturingOperations Management

(Production, Maintenance, Quality, Inventory Control)

Level 3

BatchControlSystems

ContinuousControlSystems

DiscreteControlSystems

Levels 2,1,0


4

A benefit driven approach was used to identify which business processes should be automated/integrated. The business case was developed by answering 2 questions:

1. Is there a business case to connect SAP to the Plant Applications?Improve ProductivityReduce InventoryImprove YieldEnable Yield AccountingImprove Raw Material UtilizationImprove Asset UtilizationImprove Schedule ComplianceImprove Delivery PerformanceEnable “Actual” Product Costing

PI Sheet

2. How do I connect?ManualAutomated

Point-to-PointArchitecture Based


5

Technical Architecture Overview MFG/QM

SAP R/3 4.xBAPI / RFC/ IDOC

SAP Adapter

OMII DomainCentralized DesignCentralized Build / Configuration RepositoryCentralized Monitoring

Plant Environment

• Charting• Blending

Optimizer• Meridium• …

PIM - MES IP.21

LIMSBlaze LIMS

Thermo/VG LIMS

MFG Apps

Adapter. Adapter Adapter

TIBCO Rendezvous BusXML Messaging

Shop Floor Controllers• Honeywell• ABB• Emerson

• Rockwell• Siemens• …

SF- MESProficy, Legacy

Adapter.

Enterprise Integration:

Crossworlds E*GateWebsphereMQSeries….

Adapter

Materials MgmtDataPass


6

ISA’s S88 reference model was used to define elements of the MFG application architecture.

Production Information Management

Process Management

Unit Supervision

Process Control

Physical Devices (Valves, Balances, etc.)

Manage Batch History

Recipe Management Production Planning and Scheduling

Comments and StatusInformation

Data

Master ProductionSchedule



MasterRecipe

Data

MESIntegrationPlatform

ControlIntegrationPlatform

Enterprise/Plant

IntegrationArchitecture

Manage General Recipe

Define General Recipe

Procedural Element

Define Master Recipe

Procedural Element

Legacy

Manage Site Recipe

Manage Master Recipe

SAP PP-PI

Develop Batch

Schedule

Varies –MIMI/APO/Manugistics

Manage Batch History

Manage Batches

Collect Batch and Process

Cell Information

Collect Batch and Unit

Information

PIM/MES

Manage Process Cell Resources

Acquire and Execute

Procedural Elements

Manage Unit Resources

PAS/DCS

Execute Equipment

Phases

Execute Basic Control Collect Data

BPS/PLC


7

A number of businesses processes were automated/integrated. Standard SAP PP-PI and ISA’s S95 reference model was used to create a re-useable “library” of messages.

SHOPFLOOR

DCS

MES

SAP

The Process Order is updated with phase start

A Control Recipe is Generated

User / APO releases Process Order

Goods Issue is posted and

inventory levels are updated

Goods Receipt is posted and

inventory levels are updated

Control Recipe and Process

Order are Closed

Batch is updated with

characteristics

Process Order is received by

IP.21

User / Automated

process starts the process

order

Raw material is consumed

Finished product /

semi-finished product is produced

Batch characteristic

s are recorded

Process Order is closed

LIMS

Lab Results are entered in

LIMS

Lab Results are archived

in IP.21

Material sample is sent to lab for quality assurance

The Process Order is updated

with phase activity info

Manufacturing processes execute

Material sample tested in laboratory

Material sample

Information entered in

LIMS





Posts a Goods Movement (Type 309)

Material is transferred

(btw batches, mat

#s, or locations)

Planning and Scheduling Process Lab Testing / Quality Mgmt Process

Material -to-Material Movement ProcessSent as Needed

Sent At Least Once per Control Recipe

Sent Exactly Once per Control Recipe

CUSUM Data is

presented to an operator

LIMS Operator identifies required process change

Operator takes and

confirms the corrective

actions

Corrective actions are archived in

LIMSPLCs

DEVICES RSCS TRRDTD CDTALK/DATATALK RS CSTR RDTD CDTALK/DATATALK RSCSTR RDTD CDTALK/DATATALK RSCS TRRDTD CDTALK/DATATALK RS CS TR RDTD CDTALK/DATATALK RS CSTRRDTD CDTALK/ DATATALK RSCS TR RDTD CDTALK/DATATALK

Unit ControllerUnit Controller Unit Controller

Control and Monitor Manufacturing Process

User / Automated

process starts manufacturing

process

Plant Maintenance Process

Machine utilization is recorded in

plant maintenance

Machine utilization is recorded (ie.

# of cuts, opens, etc.)

Batch Characteristic Update ProcessProcess Order Execution Process

Finite Scheduler

Process Orders are

created

Process orders are scheduled

Process Orders are updated

Process Order

Download

Process Order

Upload

Process Message (Goods Issue)

Process Message

(Batch Chrctristcs)

Process Message (Phase Activity)

Process Message (Phase Partial)

Control Recipe

(Process Order)

Process Message (Phase Start)

Process Message (Phase Finish)

Process Message (Process

Order Close)

Process Message (Goods Receipt)

Process Message (Material

Movement)

Process Message (Meas. Points)

Quality Results

Sample Login

CUSUM Data

CUSUM Feedback

Inspection Lot Results

are Requested

Results are matched to

the Requested Inspection

Lot

Inspection Lot

Request

Inspection Lot Results are Posted

Inspection Lot Results


8

Corpus Christi, TX-IP.21

Laporte, TX-IP.21

Chambers Works, NJ-IP.21SAP

Edgemoor, DE-IP.21

Kuan Yin, Taiwan-IP.21

Altamira, Mexico-IP.21

Newark, DE-LIMS (x2)

Montbrison, France-Recipe Optimizer-Finite Scheduler

Rubi, Spain-Legacy PCS

IP.21

Wuppertal, Germany-Legacy MES-IP.21

Newark, DE- SAP (x3)

Fayetteville, NC-IP.21 (x2)

Landshut, Germany-Legacy PCS

Washington Works, WV-IP.21 (x3)-LIMS

Newark, DE-LIMS

Chambers Works, NJ-IP.21

Memphis, TN-IP.21

Louisville, KY-IP.21

Pontchartrain, LA-IP.21

Delisle, MS-IP.21

Beaumont, TX-IP.21

New Johnsonville, TN-IP.21

Niagara Falls, NY-IP.21

Buffalo, NY-Legacy MES-IP.21

Dordrecht, Netherlands-IP.21

Scope of the implementation - Business Units & Plants

Interface Name Publisher Subscriber Data Structure

DTT FLPR SURF DPC DCSE

Control Recipe Download SAP MES CTRL_REC X X X X

X

Control Recipe Status MES SAP PI_CRST X X X X X

Planned/Process Order Upload Scheduler SAP - X

Inventory Download SAP Optimizer - X

X

X

X

X

X

Packaging/Labeling Upload Labeler SAP - X

Inspection Lot Request LIMS SAP - X

Inspection Lot Download SAP LIMS - X

Inspection Lot Results LIMS SAP - X

X

Phase Status Confirmation MES SAP ZPI_PHST X X X X

Phase Activity Update MES SAP PI_PHACT X X X X

Goods Issue MES SAP Z_OT_MVT X X X X

Goods Receipt – Planned MES SAP PI_PROD X X X

Goods Receipt – Unplanned MES SAP Z_OT_MVT X

Batch Characteristics MES SAP Z_BT_CL X

Material-to-Material Movement MES SAP Z_OT_MVT X

Quality Results LIMS MES QL_RSLTS X X X

In-Process Sample Login MES LIMS SMPL_LG X

In-Process Sample Login and Quality Results MES LIMS SMPL_LG X

CUSUM Data LIMS MES CUSUM_DT X

CUSUM Feedback MES LIMS CUSUM_FB X

Measurement Points MES SAP PI_PMMD X X

Usage Decision SAP MES -

Quality Notifications SAP MES -

Planned/Process Order Download SAP Scheduler -

Packaging/Labeling Download SAP Labeler -

Inspection Lot Results Feedback SAP LIMS - X

FLPR DTT

DPCSURF

3

200

CORP DCSE

1022 100

Total Annual Publications: 2,300,000 approx.

805

200


9

Business Case – Payback was achieved by the time the project was implemented.

Business Benefits

ProductivityAutomate “Feeding the Beast”

Inventory ManagementRaw Material ConsumptionsFinished goods visibility for order application

Asset UtilizationNotification of equipment utilization to trigger PM activitiesVisibility to actual shop floor productionPlants continue to run during cutover and planned/unplanned ERP outages

Activity-based CostingActual differentiated cost by product

Support Manufacturing Six SigmaEnable inter/intra plant integrationFacilitate sharing of information across the organizationImprove data accuracy across the plant systems and SAP

IT Benefits

DevelopmentProductivityEnforce architecture and application standardizationLeverage pre-built adaptersStandardize error handling, restart and recovery functionality

SupportReduce upgrade / release testing costsReduce on-going maintenance – standardized parts to support and support productivity

OperationsSupport of 7/24 manufacturing operationsProvide guaranteed message delivery by eliminating single point of failureDecrease operating costs – monitoring, alarming and recovery / restartEnhance scalability options (i.e., transaction management and load balancing)


10

Key Lessons

Leveraging existing Support Org & Processes where possibleIntegrating / Modifying Support Processes where required to support unique requirements associated with manufacturing integration

Identified key architecture considerations up frontUsed technical firsts to identify issues earlyLeveraged XML and publish / subscribe technologies to enable other plants, apps, and SBUs to more easily connect

Stringent Support Requirements7 x 24GlobalShort Response Times

Stringent Design / Build RequirementsHighly ReliableHigh ThroughputHighly Scalable and Interoperable

SuccessesChallenges

What should be automated / integrated? Business benefits identify what to automate/integrateTotal Cost of ownership drives automation/integration approach

How do you standardize given:Varying business requirements across business units and plantsVariety of legacy DCS / Plant Applications

Establish an Application/Technical Architecture vision by leveraging industry standards - SAP PP-PI, ISA, SCOR, etcMap products and tools to the Application/Technical Architecture and use this to guide all new investments Create teams with resources who can represent all business units and plantsFront End Loading to Standardize, Standardize, Standardize. We achieved:

75% common/shared messages70% shared code / config in plant apps

Shop Floor to Top Floor:

Connecting Shop Floor People, Processes, Devices and Data with SAP

Gil Rodriguez Salvatore GrassoAcsis Inc DuPont

Company Overview

• Leader since 1996• Solution Focus

– Integrated Supply Chain Solutions improving the flow of real-time transactions and information from manufacturing and Distribution to SAP systems.

• Customer Value– Streamline processes and maximize execution efficiency– Real-time access to shop floor data

• Target Markets:– Chemical, CPG, Pharmaceutical

• Customers: – 200+ of the most prestigious companies in our target markets

• Long-time SAP Partner

The Business Challenge

But, according to Gartner & AMR,more than 90% of the shop floor devices

are not connected to the Enterprise Resource Planning Systems

Companies have invested in SAP to integrate their enterprise…

…and process automation and people development to drive efficiency in manufacturing and warehouse operations

©2006 Acsis, Inc.

Salvatore Grasso

Integrated Acsis – SAP Solutions Architecture

BusinessSolutions

TradingPartner

Solutions

Pharmaceuticalse-Pedigree

CPG

Data XchangeRFID ASN

Chemical

Shop FloorAutomation

ContainerTracking

ProcessAutomation

& DeviceManagement

TransactionManagement

LabSystems

PlantHistorian

MES

MaintenanceSystems

AnalyticsRFID Analytics

Netweaver BI

Business Applications

EnterpriseLabel Mgmt

R/3 SCM PLM

PlantManager

XI

Auto-ID InfrastructurexMII

Line ManagerLine Manager

Manufacturing Distribution

Mobile Devices

StretchWrap

Open-AirEncoder Palletizer Shipping

Dock DoorOperatorConsole

LabelPrinter

RFID TagApplicator

HandheldBarcode

HandheldRFID VMU

xDDIby Acsis

More than 1000 transactions automated

• Picking– Create Pick List– FIFO Bin Display– Shipment Display– Bin Status Lookup– Goods Issue

• Inventory Management

– Stock Overview– Cycle Count– Inventory Lookup– Pallet Inventory– Physical Inventory

• Label Management– Item– Case– Pallet– Container– RFID– Barcode

• Purchasing– Create Purchase Order– Advanced Shipment

Notice– Raw Material Labeling

• Receiving– Goods Receipt– Directed / Undirected

Putaway

• Manufacturing– Consume Raw Material

• Batch Controlled• Cost Center• Back flush

– Divert product– Move product– Production Confirmation– Report Work-in-Progress– Report Production– Report Scrap

• Auto-ID Infrastructure

– Pick– Pack– Move– Ship

• Warehouse Management

– Maintain Shift Information

– Transfer Orders– Putaway– Bin-to-Bin Transfer

• Shipping– Create Delivery– Pick– Pack– Load– Confirm Delivery– Unpick Delivery– Ship Verification– Pick to Stage

Thank You

Contact Info:Gil [email protected]

dupont mfg integration to erp - american chemistry · pdf filedupont mfg integration to erp...

Documents