direct materials pi and sap the eastman experience
TRANSCRIPT
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
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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
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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
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PI/SAP Interfaces
Johnette McDanielPrincipal Systems AnalystInformation TechnologyLongview, Texas
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Pi Gateway to SAP
Eastman View
Interface Options
User View
Questions
PSRLink Overview
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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
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Pi Gateway to SAP
Eastman View
Interface Options
User View
Questions
PSRLink Overview
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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
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Pi Gateway to SAP
Eastman View
Interface Options
User View
Questions
PSRLink Overview
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Interface Options
Standard PI-PCS Interface
SAP to PI-Tag Value Updates
Material Movement Interface
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Interface Options
Standard PI-PCS Interface
– Start/Stop Control Recipes
– Start/Stop Phases
– Report Production
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SAP R/3
PP-PI
PSRLINK
PI
PI-SAP Automated Interface to PP-PI
Process
Instructions
Control Recipes
Process Messages
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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
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SAP R/3
PP-PI
PSRLINK
PI
PI-SAP Automated Interface to PP-PI
Process
Messages
OSI_COMM
Messages
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Interface Options
Material Movement Interface
– Eastman driven enhancement
provided by OSI
– Unsolicited Messages sent from
PI to SAP
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SAP R/3
PP-PI
PSRLINK
PI
PI-SAP Automated Interface to PP-PI
Unsolicited
Process Messages
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Pi Gateway to SAP
Eastman View
Interface Options
User View
Questions
PSRLink Overview
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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
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Batch Production Reporting PB
PSRLink System Management PB
PSRLink Interface ProcessBooks in LAR
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Batch Production Reporting PB
PSRLink System Management PB
PSRLink Interface ProcessBooks in LAR
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Batch Production Reporting ProcessBook
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Batch Production Reporting PB
– Start/Stop Control Recipes
PSRLink Interface ProcessBooks in LAR
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Start / Stop Control Recipes
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Batch Production Reporting PB
– Start/Stop Control Recipes
– Start/Stop Mix Tank Batches
PSRLink Interface ProcessBooks in LAR
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Start / Stop Mix Tank Batches
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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
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Start / Stop Batches and Report Production
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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
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Batch Reports from Datalink to Excel
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Batch Production Reporting PB
PSRLink System Management PB
PSRLink Interface ProcessBooks in LAR
EASTMAN33
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PSRLink System Management PB
– PSRLink Applications
PSRLink Interface ProcessBooks in LAR
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Error Log Review
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PSRGUI
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Configuration
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Access View of SQL Server Tables
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PSRLink System Management PB
– PSRLink Applications
– SAP Links
PSRLink Interface ProcessBooks in LAR
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CO53 - Display Control Recipe Monitor
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CO54 - View Process Message Monitor
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View Gateway Monitor
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PSRLink System Management PB
– PSRLink Applications
– SAP Links
– Debugging Documentation
PSRLink Interface ProcessBooks in LAR
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PSRLink System Management PB
– PSRLink Applications
– SAP Links
– Debugging Documentation
– Problem Alarms
PSRLink Interface ProcessBooks in LAR
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PSRLink System Management PB
– PSRLink Applications
– SAP Links
– Debugging Documentation
– Problem Alarms
– PSRLink Program Status
PSRLink Interface ProcessBooks in LAR
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Pi Gateway to SAP
Eastman View
Interface Options
User View
What we have learned
PSRLink Overview
EASTMAN53
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Manufacturing Enterprise Systems Alignment
Questions & Discussion...
Sharing ideas for a shared future.....