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OSI Software, Inc
PI System Users’ Conference
Monterey, California
POLIMERI EUROPA
AN ENICHEM | UNION CARBIDE VENTURE
Ing. Carlo Volpones
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Taking SAP to the Factory Floor
an
Italian Experience
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Agenda
• Company Profile
• Program Opera
• Management and Technology Challenge
• Company Key Decisions
• Implementation Partners
• Manufacturing Implementation
• 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 1995
Year 1999
• Sales Revenue
1.4
1.6
Billion USD
• Total Capacity
1,400
1,600
Polyethylene kty
600
600
1,626
1,571
• Employees
Ethylene kty
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Polimeri Europa Principal Manufacturing Facilities
Oberhausen

Dunkerque


Eschborn
Milan  
Ferrara
Brindisi

Ragusa

 
Gela
Priolo
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Key Investments for the Polimeri Europa
Joint-Venture
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• 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
Completion date
Total investment
Technology
Total capacity
Production lines
Type of products
Customer satisfaction
1st January 1995
1st September 1997
greater than xx million USD
UCC Gas Phase
400 Polyethylene kta
2 lines
LLDPE-HDPE
High Level of Acceptance
• First company implementation of OSI, RTDB
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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 effectivness 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
 Process
 Geograp
hy
Germany
 Application
Solution
SAP R/3 Standard vers. 3.1
Executive
Fulfill
Demand
Balance
Supply &
Demand
Service
Customer
Business Infrastructure
Create
Demand
FI
QM
PS
TR
WM
SD
IM
PP-PI
EIS
CO/CCA
PM
HR
AA
SD SHP
MM
LC
Scientific Systems and
Niche Applications
RTDB
LIMS
SCM
Transportation
France
Italy
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Management and Technology
Challenge
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Management Challenge
Assessment of Current Situation
(Starting Point Fall 1996)
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• 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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Technology Challenge
Assessment of Current Situation
(Starting Point Fall 1996)
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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
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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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IT Company Infrastructure
Milan Head Office
Router
Eschborn
Public Network
Paris
Dunkerque
Ragusa
Ferrara
Polimeri WAN
Brindisi
Gela
Priolo
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Business Integration Using New Applications
Head office
Local offices
Customer
Stock
Profit
Center
Company
code
Distribution centers
Transport
order
Message/
Event
Handler
Warehouses
Material
Factories
Production
order
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Implementation Partners
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Implementation Partners
Hewlett Packard
Polimeri Europa
Hardware and system software
• Head office
• 7 plants
• many warehouses
(MGC)
OSI (Synapsis)
Ernst & Young
Managing General Contractor
OSI (Synapsis)
RTDB
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Defintion of Operations Work Processes
Process Technology
Manufacturing
and Engineering
Sub Processes
Manufacturing
Manufacturing
Maintenance
Maintenance
Sub Processes
Sub Processes
• Process Enigineering
• Plant line schedules
• Technology Development
• Prodcution
• Engineering
• Quality Control
• Plan & Schedule
Maintenance
Activities
• Execute
Maintenance
Activites
• Maintenance
Engineering
HS&E
HS&E
Sub Processes
• Environmental
Compliance
• Process Safety
• Product Safety
• Personnel Safety
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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 batch and continuous
operations
• Finished product is packaged and sold to customers in
batches
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Overarching 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 automaticaly
• Plant operators have one and only one interface for data
input
• Production Planning is compiled at headquarters with
detail execution at the plants
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SAP Modules Utilized for the
Integrated Manufacturing Solution
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• 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 modelled 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
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• Production managed as campagins : production quantities calculated
of materials consumed and resources utilized for each finished
product.
• Economic analysis (cost summaries, and efficincey 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 (continued)
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• Advancement of production interfacced with RTDB
• Available to Promise (ATP) updated in real time with planned transfers
relative to production orders.
• Raw material to finshed 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
Phase
Closure
SAP PP_PI
Information from RTDB :
.) Finshed lot Product tests.
.) Quantity of Finished product transfered to Silos
.) Quantity of Raw materials by lot consumed
.) Quantity of Raw materials non lot consumed
Finished Product lot tested transfers
Consumption (actual and std.) raw material (by lot and non)
WM
SAP MM
SAP FI
Production
Campagin
Lot Traceability
Reports
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Production
Campaign
Cost Reports
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Implementation Design - Components
• PI 3.2
Real time data historian, Batch
Monitor and totalizations
• PS-RLINK
PI system gateway to SAP R/3
PP-PI module
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• PI-ProcessBook 2.0 Graphical representations and
PIBatchView
management of:
- Process data (PI)
- Process Order (SAP Recipe)
SYNAPSIS
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Implementation Design - Infrastructure
Milan Head Office
SAP
PI ProcessBook
PI ProcessBook
Public Network
Polimeri WAN
PI ProcessBook
PLANT SUITE
RLINK
PI Home node
SITE
DCS
SYNAPSIS
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Implementation Design - Model
• 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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SYNAPSIS
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Implementation Design - Data Sources
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 the recipe standard
SYNAPSIS
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Implementation Design - Data Sources solution
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
RESULT: ALL IS IN PI SYSTEM
SYNAPSIS
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Priolo Plant
PRIOLO PLANT DETAIL
BlenderA
BlenderB
Silos
Reactor
BlenderC
BlenderD
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Priolo Units
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 transfered to Silos
Unit Information
-> Start and End Phase
-> Material Quantity
Consumed/ Produced
-> Phase ID
-> Recipe ID
-> Phase confirmation Type
(Partial/Finished)
SYNAPSIS
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RESOURCE AND PHASE - ONE PROCESS ORDER
MANY PHASES CONFIRMATIONS
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ORDER
1
order_pi_status
order_sap_recipe
0
CRID1
PHASE
Start
Partial
CRID1 CRID1
Partial
CRID1
End
phase_sap_status
CRID1 CRID1
phase_sap_recipe
Partial
Start End/Start End/Start End/Start
L1
L2
L3
End
L4
phase_pi_status
phase_lot_number
TIME
SYNAPSIS
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PB Display - Overall view
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Blenders Details
Reactor Details
SYNAPSIS
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PB Display - Reactor
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SAP Process Order
Information
PLANT_SUITE
Process Information
PI
Viewing Lots in Reactor
SYNAPSIS
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PB Display - Reactor
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New Campaign
Selection Window
Lot Details
Window
SYNAPSIS
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PB Display - Blender
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Process Information
PI
Moving Lot across Blender and Silo
SYNAPSIS
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PB Display - Silos
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SAP Process Order
Selection
PLANT_SUITE
Viewing lots in Silo
(Selected Process Order)
PI
SYNAPSIS
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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 facilitiy management of client server
environment
• integration of information systems from DCS through
RTDB to SAP business reporting systems
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Closing Observations
• SAP and RTDB 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 managment.
• 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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Polimeri Europa System Integration Project