steelman sems ebs addon for mills

Steel Enterprise Management Systems® SEMS(tm)

Steelman™ Software Solutions Inc.Metal Software That Changes With Your BusinessMetal Software That Changes With Your Business

© Copyright 2010 Steelman Software Solutions Inc. All rights reserved. Confidential and Proprietary

Steel Specific “Knowledgeware”

• Our strength comes from a proven understanding of the steel business gained from hands on experience– Successful system implementations– Extensive steel industry consulting history– Steel management and sales experience– Experience at:

• Mills• Processors• Service Centers• Fabricators


About Steelman

• VSZ a.s. - fully integrated steel mill 3.6mt• CSC Ltd. - speciality bar mill 1mt• Parkdale International – service center• Midland Steel – tool steel service center• Pacesetter Steel Services – 5 service centers• Wheeling Pittsburg Steel Corporation – fully integrated

steel mill• Steel Warehouse Company – 12 service centers• Olympic Steel – 15 service centers incl. fabrication


Steelman Product History

BUILT on ORACLE DATABASE & APPLICATION SERVERS

Hot Rolling Mills

Cold Rolling Mills

Service Centers

Outside Processors

Assembly Fabricators

SEMS

MFSteel Mill Melt Shop

Launched 1996

Launched 2003


International CapableExample SEMS Handles

• Require separate SEMS company– Company currency in Paso– Company document in Spanish– Unique taxation issues– Can translate all screens in Spanish

• Changes in Accounting procedures– Inventory valuation does not include taxes– Exchange rate is changed daily– Mexican invoice need amounts spelled out in Spanish

• Duty and customs documents (NAFTA)• Ownership change only happens when goods cross the

border


Current Locations and Teams

• Head Office– 4850 Keele St. First Floor

Toronto, Ontario M3J 3K1 Canada

– Telephone 416.495.6939• USA Project Office

– Cleveland, Ohio, United States

• Reseller Offices– Kosice, Slovak Republic– Mumbai, India– Monterey, Mexico– Shenzhen, China

• Large core team of steel application and project experts

• Steelman comprises a team of over 50 people

• Through our offshore partner offices we can scale to any project size with experienced staff


THE STEELMAN APPROACH

• The knowledge gained, and the approach and methodology have been developed by working on the shop floor with the experts – i.e. the Operators - in defining the parameters, rules-of-thumb and general heuristics that have to be incorporated into the solution to realistically provide tools that lead to change in both operating practice and procedures


Examples of Previous Successful Projects Utilizing the Approach and Methodology That Now Form the Nucleus of the STEELMAN Solution Include;

• Republic Engineered Steels, 1990 -1992; Development and implementation of:– A Production Planning tool

(Heat Build Module) which was utilized to group all orders into “Buckets” of strings of heats.

– A Production Scheduling Tool for the Melt Shop and Cast Roll Facility.

– A Grade Salvage Tool, which would determine the “best” alternative for processing an off-grade heat.

• USS/KOBE Steel Company, 1991- 1994; Development and implementation of a Production Scheduling tool.

• AHMSA Mexico, 1995 – 1998; Provided consulting and management assistance to the steelmaking division to study and improve their logistical practices and systems.


Examples of Previous Successful Projects Utilizing the Approach and Methodology That Now Form the Nucleus of the STEELMAN Solution Include;

• VSZ a.s. Kosice, Slovakia, 1995 – 1999; Development and implementation of the Enterprise wide STEELMAN Steelmaking Software System for Flat Products, for the 3.6 million tonne/year steel producer.

• CSC Ltd, 1999- 2001, Development and implementation of the Enterprise wide STEELMAN Steelmaking Software System for Long Products, for the 1 million ton/year steel producer.


Solution Objectives

• Streamline business flows• Superior customer service

– Capability to promise– Available to promise

• Improve productivity• Improve quality• Reduce cost and working capital• Informed decisions• Move to an open and homogenous technology

environment


Order To Cash

Supply ChainPlanning

Scheduling &Execution

Customer

Customer ServiceProduction Plant

Shop Floor

Management

Actual /Planned Demand

BusinessStrategy and Rules

Availability to Promise

Capability to Promise

Material &ResourceStatus

ActualPredictedPerformance

ProductionSchedules

Connect Customer, Manager and Plant


http://images.google.com/imgres?imgurl=www.clev.frb.org/research/Et2000/0400/Html/Charts/steel2c.gif&imgrefurl=http://www.clev.frb.org/research/Et2000/0400/Html/steel.htm&h=363&w=370&sz=6&tbnid=digzgBGN2H4J:&tbnh=115&tbnw=117&start=136&prev=/images%3Fq%3Dsteel%2Bmill%26start%3D120%26hl%3Den%26lr%3D%26ie%3DUTF-8%26sa%3DN

Financial SuiteFinancial SuiteSales/AR

Cash MGT

GeneralLedger

AP PayrollHR

EDIEDI

ScheduleCreated

Material Assigned

Web Development

Web Development

ClaimsClaims

CostCost

CommercialManagement

ProductDesign

Manufacturing Control

Order StatusManagement

RepeatOrder

Referrals

OPEN

Accept

CUST

Reject

OverrideAccept

ProductionRecording

DefectsScrap

InventoryChecked

Product Routing

CUSTOMER

Shipping & Gate Exiting

Carrier In

OK--Promise

Date

NewOrder

Quality

OrderEntry

Inquiry

DynamicRouting &

Provisioning

DistributionManagement

STEELMANDATABASE

BASE BOM/FORMULAS& ROUTES

SALESORDER

PROJECTEDSALES

DYNAMICROUTING &

PROVIONING

MATERIALPLANNER

PRODUCTION PLANNER

BUSINESSOPTIMIZER

COSTVARIANCE

AR& GL

LOAD BUILDING &

SHIPPING

MES WORK ORDERS ON

PRODUCTIONFLOOR

PRODUCTIONSCHEDULER

WORKORDERS

ORDERENTRY

DEMANDMODELER

STANDARDCOSTING

COMMERCIALDRESSING

PRICING

WIPINVENTORY

AP & RAWMATERIAL INVENTORY

PromiseDates

ALTERNATEPROVISIONEDROUTES

ALTERNATEPROVISONEDROUTES

ATTRIBUTES

SOLUTION INTEGRATIONSTEELMAN – 3rd PARTY FINANCIALS

EXISTING SYSTEMS 3RD PARTY FINANCIALSSTEELMAN

CTP & ROUTINGINFORMATION

CONFIRMEDORDER

ATP CTP

InquiryDetailsCONFIRMED

ORDER

Schedules

Inventory

StatusReady DatesALTERNATE

PROVISIONEDROUTES Actual

Production

Dressed Work Orders

ORDER ENTRY

ORDER ENTRY

CLIENTORDER

CLIENTORDER

PROVISIONINGPROVISIONING

PLANNINGPLANNING

DRESSINGDRESSING

SALESORDER

SALESORDER

WORK CENTRELOADING

WORK CENTRELOADING

SALES ORDERMASTER PLAN

HEATBUILDHEAT

BUILD

STANDARDCOSTING

STANDARDCOSTING

PLANNING &SCHEDULINGINTERFACE

TOOLS

PLANNING &SCHEDULINGINTERFACE

TOOLS

WORK CENTRELINE-UPS

WORK CENTRELINE-UPS

PRICINGPRICINGSHIPPING

DOCUMENTSSHIPPING

DOCUMENTS

PRODUCTIONREPORTING

PRODUCTIONREPORTING

FINANCIALMODULES

FINANCIALMODULES

EXECUTIVEREPORTING

EXECUTIVEREPORTING

FINANCIALSTATEMENTSFINANCIAL

STATEMENTS

INVENTORYINVENTORY

PRODUCTION DATA

REPORTING

PRODUCTION DATA

REPORTING

MAINTENANCEMAINTENANCE

Fabrication BOM

Parts Mfg

Accounting GL, AR, AP, Financials Reporting Accounting GL, AR, AP, Financials Reporting

Quotes-Sales Order

Contract Mgt

Quotes-Sales OrderContract Mgt

Plant SchedulesProduction Plans

Plant SchedulesProduction Plans

MaterialAllocator to Orders

MaterialAllocator to Orders

Pricing &Costing Models

Pricing &Costing Models

Oracle10g AS & DB

Oracle10g AS & DB

Production Orders & Recording

Production Orders & Recording



Work OrdersProvisioning

Work OrdersProvisioning

Product CatalogInventory Mgt

Product CatalogInventory Mgt

Partner MgtCustomer-Vendor

Partner MgtCustomer-Vendor

PurchasingSupply Chain Mgt

PurchasingSupply Chain Mgt

Packaging

Load Planning

Shipping-Logistics Mgt

Invoicing / BOLS / Ack / Mill Certs

QA and Test Mgt

Heat Management

Claims Mgt

Customer & Vendor

CAR –Corrective Actions Reporting

ISO Standards Compliances Constant Improvement

Programs

Document Mgt

PDF, CAD, Photos,

MS-Office Docs, Scanned Images

BI Reporting Tools

Business Intelligence Reporting & Creation

Data Warehousing Options in SEMS system

Steelman SEMS® Integrated Software Solution


Sales Order Management

• Inquiries, Blanket and Spot Orders

• Repeat Orders search and retrieval

• Offerings• Auto Pricing/costing with

manual override• Tracking of Order changes• Tracking of Inquiry

expiration• Real-time Order status• Inter-co sales or transfers• Customer self service• Privilege driven security

FinancialsFinancials

Customers Internet Phone EDI/XML

Customers Internet Phone EDI/XML

Standard Costing

Standard Costing

Oracle10g AS & DB

Oracle10g AS & DB



Work Instructions

Work Instructions

ProductCatalog

ProductCatalog

CustomerManagement

CustomerManagement

Sales OrderManagement


ProductionManagement


MaterialAllocator

MaterialAllocator


InventoryAllocations

SEMS Master Contract ManagementCreate MasterContract with

CustomerDefine Period &

Distributions

Products Specifications

Pricing

Releases MgtAgainstPeriod

Distribution demands

Scheduled Master Sales Order

Confirmation

Packaging, Shipping

StatusInvoicing, BOLs

Credit Mgt

Sales HistoryClaims mgtContract

Purchase OrdersCreated

For Distributions

Production Orders &Status for

Distributions

ProductProcessing Work

InstructionsConfiguration

Master Contract Mgt Screen Manages-Reviews all functions


Master Order – Contract Mgt


ProductionPlans

Schedules

Quotes/Sales ManagementCreate Quotes

Change to SalesOrders

Firm Orders

Product SpecsReview Sales History

WINS-LOSSESInventory Available

Price Order

Create WorkInstructions

Schedule OrderConfirmation

Finalized Work Order

Release toManufacturing

Create Provisioned Route or BOM

InventoryAllocation

Shipping InstructionsPromised DeliveryDates –CTP/ATP


Quotes & Sales Order Header


Sales Order Line Items


Customer Management

• Communicate to customer in their “language”

• Customer preferences• Customer part definitions• Customer based pricing• Hierarchical corporate

structure• Multiple Bill-to/Ship-to per

Sold-to• Multiple units of measures• Multiple currencies• Link to AR for credit control• Integrated issue resolution

with claims management


CustomersCustomersSales Order

Management


MaterialAllocator

MaterialAllocator

Standard Costing

Standard Costing

Oracle10g AS & DB

Oracle10g AS & DB



Work Instructions

Work Instructions

ProductCatalog

ProductCatalog

CustomerManagement

CustomerManagement




Product Catalog

• Attribute Based (Not SKU based)

• Flat or hierarchical structure• Track by weight, pieces,

linear measure or square measures

• Full steel-industry specific product specifications:– Product type; end-use– Multiple product shapes– Dimensions & tolerances– Grade, quality, industry

standards– Chemistry– Predefined /special tests &

processes



Management


Standard Costing

Standard Costing

Oracle10g AS & DB

Oracle10g AS & DB



Work Instructions

Work Instructions

ProductCatalog

ProductCatalog

CustomerManagement

CustomerManagement



MaterialAllocator

MaterialAllocator


“Tag # assigned” Inspected

Tested Mill Certs

Properties added

Demand Planning Purchasing ManagementReview Demands

Product-Customer Use ForecastedDemands forPurchasing

Create Purchase Order & Pricing

Using Mill Pricing Agreements

From CustomerSales HistoryProjections

Linked

Costing VerifiedMaterial

TransportationSurcharges

Save to InventoryAllocations to Orders

Warehouse Mgt

3-WayMatching Of

Invoices- P.Orders &BOL.s Freight mgt

Review In-transitPurchaseOrders

ReceiveOrders

IntoInventory

OptimizeProduct

PurchasingOrders

Due to Demands

GL & AP Postings

Supplier-ShippingInvoicing mgt


Demand Planning 5 Ws

• What to buy?– Grade, Properties, Dimensions…

• When to buy?– Time phased, forward looking

• Where or location requirements?– By department, regional demands

• What we have in stock – Free and allocated

• And, What Quantities to buy?© Copyright 2010 Steelman Software Solutions Inc. All rights reserved. Confidential and Proprietary

Inventory Control Demand Plans


Work Instructions

• Dynamic Routing and Provisioning

• Technical & commercial instructions are added

• Instruction can be manually over-ridden

• Processes are user definable

• Stock allocation using intelligent attribute-based search

• Outside processing• Allows to provide realistic

ATP & CTP



Management


Standard Costing

Standard Costing

Oracle10g AS & DB

Oracle10g AS & DB



ProductCatalog

ProductCatalog

CustomerManagement

CustomerManagement

Work Instructions

Work Instructions

MaterialAllocator

MaterialAllocator




Production Plans Cutting Planner


Standard Costing

• By line items for all inquiries and orders

• Table driven:– Unlimited cost buckets– User defined cost types and rules

• Shop floor activities are applied to individual Orders

• Cost of WIP is accumulated based on Level2 Data

• “Actual vs. Standard” variances include:– Efficiency variance– Material usage variance– Material price variance

• GL booking by cost types available for further analysis



Management


Oracle10g AS & DB

Oracle10g AS & DB



Work Instructions

Work Instructions

ProductCatalog

ProductCatalog

CustomerManagement

CustomerManagement

Standard Costing

Standard Costing



MaterialAllocator

MaterialAllocator


Distribution Management

• Record production results • Track physical locations• Maintain history of all

transactions • Store heat chemistry and test

result on items• Trace tag genealogy back to

original heat• Create customized shipping

tags by customer• Dispatch shipments• Generate BOL, Invoices and

Customs documents• EDI, RF & barcode enabled



Management


Standard Costing

Standard Costing

Oracle10g AS & DB

Oracle10g AS & DB

Work Instructions

Work Instructions

ProductCatalog

ProductCatalog

CustomerManagement

CustomerManagement



MaterialAllocator

MaterialAllocator




Logistics Load Shipping


Issue to resolutions

• Online claims management

• Each department is dealing with same customer record

• No need to waste time

• Sales and service work together to generate income


Claim Management

Multiple defects per tag, using industry

standard or customized

codes

Claims can be generated

for any shipped tag and invoice

Complete logging of all

stages of investigation

claimed material can be marked for return, for

credit or rejected


Oracle Database & Application Servers

Oracle10g Database

Server in a RAC

STEELMAN Data

Browser/Device

Level 2MES

Oracle10g Application Server in a

Cluster

STEELMANApplications

CollaborationTools

Advanced Search

Content Management

Business Intelligence

Workflow


Built-in Business IntelligenceAnalyze Data In Real-time

• Industry leading, award winning reporting / analysis tool

• Management and operational info on the fly

• No programming required• Drill-up; drill-down capabilities• Powerful, yet easy to use• Reports can be incorporated

into system once developed• Export to excel & other file

formats

Key Module

• Business Partner Management (BPM)• Product Configuration• Sales Management• Production Management• Warehouse Management• Costing• Shipping• Claims Management• Quality• Reports and Business intelligence

NEW

Oracle BI

Publisher


Proposed Solution – Business Flows

• STEELMAN Steel Enterprise Management Systems®– Order to Cash

• Configure Quote to Order• Order Management• Routing Provisioner

– Forecast to Plan• Advanced Planning and Scheduling

– Plan to Build• Process Manufacturing• Caster Sequencing

– Call to Resolution– Business Intelligence


OrderManagement

Integrated Logistics

Schedule

PlanShipmentShip &

Track

Invoice/Payment

Price

CheckAvailability

Capture

Configure

Tailorable,Workflow

DrivenProcess

Complete Business Flow

Web Store

Call Center

Sales / Quotes

XML/EDI

ContractRelease

Service

Multi-Channel Demand

Collaboration

Planning

Purchasing

Manufacturing

TransportationManagement

WarehouseManagement

Finance

CustomersSuppliers


Advanced Planning

Time

Pla

nn

ing

lev

el

Supply Chain and Manufacturing Planning

Inventory Optimization

Minutes Hours/Days Weeks/Months Quarters Years

Order Promising

Supply Chain Intelligence

Supply Chain Event Management

ManufacturingScheduling

Collaborative Planning

Demand Planning


Process Manufacturing

Create Sales Order

Procure Materials

Capture Costs;Analyze Variance

CaptureCustomer Demand

Analyze QualityAuto-Allocate

Schedule Production

Create Recipe (if custom)

Produce Batch Ship Product

Manage RegulatoryDocuments

Assign Lots UpdateAR / GL

Closed-Loop Demand to Build Offering


Close the Loop On Your Business

• Reduce redundant data entry & maintenance

• Real-time visibility across enterprise

• Built in business intelligence tools

• Web deployed• Infinite scalability with

Oracle infrastructure• Integrates to ACCPAC or

ORACLE financials

ShipShip

FulfillFulfill

Plan

Finance

ShipShip

ProcureFulfillFulfill

Maintain

Manufacture

Order

Sell

Maintain


Project Management

Daniel Brody

Project Director


Methodology: ERP/MES Project Lifecycle

Step 1: Discovery• The first step in Steelman Software Solutions’ ERP/MES project lifecycle is to work with our clients to develop a strategy for incorporating

MES into their enterprise. Our ‘SEMS System Assessment’ allows clients to discover and define their ERP/MES strategy in terms specific to their operations, while at the same time ensuring that all potential areas of improvement are identified.

Step 2: Framing the Solution• Once the ERP/MES strategy has been identified, it is time to move towards framing the solution. This involves: • Defining Functional Requirements • Defining System Architecture • Prototyping any GAPS discovered in the initial Discovery phase• Developing an Implementation/Project Plan • Developing a Change Management Plan

Step 3: Implementation• Once the strategy has been developed and the framework designed, it is time to implement. To keep costs at a minimum, while ensuring

a seamless solution, Steelman Software Solutions follows a very structured implementation methodology that includes: • Detailed Design and from a Process Design using Business Process Improvement methodologies• Functionality Testing including database, hardware, network, and processes including work flow analysis• Data Conversions• Installation • Training • Support including a web site for Project Management, Metalink reporting site for SEMS issue resolving and client needs and custom job

planning, tracking tools and scheduling interfaces with our support/development team.


Steelman’s Services for Success

18 to 24 month project implementation estimateDepending on number of unique lines of business


Delivering Results

• On time• On budget• Meeting or exceeding

expectations• Quality control• Integration• Versatility• Standardized product


On Time

• Understand Needs• Have a standard

approach• Projects/Tasks/Sub tasks

definition• Be realistic• Plan ahead• Great Communication• Hands-on testing and

training


On Budget

• Document requirements in discovery

• Simulate real life events• Consult on best practices• Experienced project

leaders• Detailed estimates• Real understanding• High-quality development


Meeting or exceeding expectations

• Quality control at all stages

• Close collaboration – Metalink

• Insight and standard versatility of SEMS

• Prototyping• Added value


Quality Control

• Do the right thing ..right• Realistic test suite• Detail testing pre system

design• Quality process• Communication• Standards

Customer


Versatility

• Configuration options• Site flags• Enhancements• Collaboration• Prototyping• Best practices


Standardized Product

• One code set• Release control• Version Control• Standard UI• Documentation• Development process


Summary

• State-of-the-art technology• Steel-specific screens, features & workflow:

– Easy to train; no cultural shocks– Fast implementation; no major tweaking as in the

case of “Vanilla” ERP system

• Scaleable, customizable, and attribute based – important criteria for interface to

• Perfect fit – Steelman provides all the missing pieces Your needs


Know More.Do More.

Spend Less“EMPOWERING YOUR TEAM”

Metal Software That Changes With Your BusinessMetal Software That Changes With Your Business


steelman sems ebs addon for mills

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