1999 pi system users’ conference monterey, california

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1999 PI SYSTEM USERS’ CONFERENCE

1999 PI System Users’ ConferenceMonterey, California

POLIMERI EUROPAAN ENICHEM | UNION CARBIDE VENTURE

SYNAPSIS

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Taking SAP to the Factory FloorTaking SAP to the Factory Floor an an

Italian ExperienceItalian 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 systemFirst 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

ItalyFrance

Germany

Process Application SolutionSAP R/3 Standard vers. 3.1

FI EISQM CO/CCAPS PMTR HRWM AASD SD SHPIM MMPP-PI LC

Scientific Systems and Niche ApplicationsRTDBLIMSSCMTransportation

Executive

Business Infrastructure

FulfillDemand

BalanceSupply &Demand

CreateDemand

ServiceCustomer

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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

RagusaDunkerque

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

Transportorder

Productionorder

Factories

Stock

Local offices

ProfitCenter

Material

WarehousesMessage/EventHandler

Distribution Centers

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Definition of Operations Work Processes

HS&EHS&EMaintenanceMaintenance Manufacturing Manufacturing

Sub Processes

• Plant line schedules

• Production

• Quality Control

Sub Processes

• Plan & ScheduleMaintenanceActivities

• Execute MaintenanceActivites

• MaintenanceEngineering

Sub Processes

• EnvironmentalCompliance

• Process Safety

•

Product Safety•

Personnel Safety

• Process Engineering

• Technology Development

• Engineering

Sub Processes

ManufacturingProcess Technology and Engineering

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Implementation Partners

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Implementation Partners

(MGC)(MGC)

Hewlett PackardHardware and system software

OSI SOFTWARE(Synapsis )

RTDB

Ernst & YoungManaging 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 theIntegrated 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 rawmaterial, 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 FISAP MM

Production CampaignLot Traceability Reports

Production Campaign Cost Reports

Finished Product lot to test transfersConsumption (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 ProcessBookPI ProcessBook

PI ProcessBook

PI Home nodePLANT SUITERLINK

DCS

SITE

SAP

SYNAPSIS

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Implementation Design - Model

SYNAPSIS

• Process Order Stored in Plant Suite Managed as a PI Batch Unitwith 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 PlantReactor -> Duration Phase: ~ 4 hours -> By-product is moved to one Blender every phase confirmationBlender -> 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_statusorder_sap_recipe

0

1

CRID1

PHASE

phase_lot_numberL1 L2 L3 L4

phase_sap_statusStart Partial EndPartial Partial

phase_pi_statusStart EndEnd/Start End/Start End/Start

SYNAPSIS

phase_sap_recipeCRID1 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 InformationP 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 InformationP 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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1999 pi system users’ conference monterey, california

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