1. 1 Manufacturing Systems Integration at

2. 2 MA Hanna Yesterday Headquartered in Cleveland, Ohio Employs 7,000 people worldwide $2.3 Billion in Sales - 1999 Resin Distribution $ 460 million Rubber Compounding $ 529 million Color Compounding $ 483 million Plastics Compounding $ 437 million Shapes $ 391 million Headquartered in Cleveland, Ohio Employs 7,000 people worldwide $2.3 Billion in Sales - 1999 Resin Distribution $ 460 million Rubber Compounding $ 529 million Color Compounding $ 483 million Plastics Compounding $ 437 million Shapes $ 391 million

3. 3 Geon Yesterday Headquartered in Avon Lake, Ohio Employs 3,100 people worldwide Worlds largest producer of vinyl (PVC) compounds $ 820 Million North Americas largest producer of dispersion resins & formulators $ 235 million Engineered Films $ 215 million Joint Venture with OxyChem (OxyVinyls) & various joint ventures worldwide Headquartered in Avon Lake, Ohio Employs 3,100 people worldwide Worlds largest producer of vinyl (PVC) compounds $ 820 Million North Americas largest producer of dispersion resins & formulators $ 235 million Engineered Films $ 215 million Joint Venture with OxyChem (OxyVinyls) & various joint ventures worldwide

4. 4StrategyStrategyPolymers Additives Appliances & Business Equipment Packaging ConsumerProducts Consumers Communications/ Electronics Designer/Assembler COMPOUNDERS PROCESSORS Service & Distribution Building Materials Automotive Packaging Consumer Products

5. 5 Manufacturing Integration History Manual Plant pilot Scope & Design User Views Automated Plant Project Scope & Design, Data Views Lessons & Experiences Questions? Manufacturing Systems Integration at

6. 6 l This initiative was focused in large part on our compound manufacturing assets and product line. Supplier(s) Customer(s) Sell-Service Design-Make Source Logistics-Delivery Close Sale Receive Payment Order Fulfillment Procurement ManufacturingOrder Processing Planning In 1988, we began our Computer Integrated Enterprise vision by attempting to simplify, automate and integrate our internal processes

7. 7 Corporate Process Model (SCADA) Manufacturing Execution System (MES) - PROCESS/1 Inventory Management Procurement Planning Forecasting/ Planning System Order Entry System Financial System FG / Shipping System Raw Material Inventory System Run Tracking Process Control GENERAL STORE Distribution Plant Line SID LIMSCHAMPS NT Geons Computing Environment

8. 8 High Level Information Flow PREPARE FOR PRODUCTION RUNS EXECUTE PRODUCTION RUNS ANALYZE PRODUCTION RESULTS INPUTS KEY FUNCTIONS OUTPUTS/ INPUTS KEY FUNCTIONS OUTPUTS/ INPUTS KEY FUNCTIONS OUTPUTS MATERIAL DELIVERIES PRODUCTION SCHEDULE/ BOM SPC/SQC ANALYSIS RESULTS RECIPE ADJUSTMENTS PREPARE LINE RECIPE PACKET ORDER, RECEIVE, AND BAR-CODE MATERIALS SET UP SPC SPECS LOT SPECIFIC RECIPE PACKET SPC SPECS BAR-CODED RAW MATERIALS PICK RAW MATERIALS FOR 3RD & 4TH FLOOR MAKE-UP BULK, MASTER BATCH AND HAND-ADD MATERIALS EXECUTE, CONTROL, AND MONITOR RUN TRACK ACTUAL RUN PERFORMANCE RUN HISTORY: PRODUCTION RUN AUDIT TRAIL MATERIAL USAGE FINISHED GOODS PRODUCTION RUN START/STOP TIMES DOWNTIME EVENTS SALVAGE PROCESS VARIABLES MATERIAL PERFORMANCE VIEW/UPDATE ANALYZE RUN PERFORMANCE PERFORM SQC ANALYSIS RUN PERFORMANCE MEASURES PRODUCTION RUN AUDIT TRAIL SPC/SQC ANALYSIS RESULTS

9. 9 The Manufacturing Systems Journey EXECUTE PRODUCTION RUNS CONTINUOUS IMPROVEMENT PREPARE PRODUCTION RUNS ANALYZE PRODUCTION RUNS INCREASE QUALITY AND CONSISTENCY COMPETITIVE COSTS CUSTOMER RESPONSIVENESS SIMPLIFICATION

10. 10 A Manufacturing Pilot is recommended to close gaps between sites, leveraging best practices and information driven capabilities Manufacturing Decision Support standard decision support tools common measures across sites common basis for comparisons data warehouse at each plant (compound and specialty resin) and corporate Data Acquisition standard data acquisition approach standard data elements standard data structure Manual data capture where controller data feeds unavailable Line Recipe Management LRM capability extended to plants where it does not exist PRM can be supported with more common skills Mfg. Systems Strategy Study

11. 11 Mfg. study revealed several things: The Major drivers are Technical obsolescence No viable solution to offer non-legacy plants There is no single piece of functionality that is driving the savings Timing of the SAP 4.6 upgrade is critical to our plan of action The Major drivers are Technical obsolescence No viable solution to offer non-legacy plants There is no single piece of functionality that is driving the savings Timing of the SAP 4.6 upgrade is critical to our plan of action Mfg. Systems Strategy Study

12. 12 Manufacturing Integration History Manual Plant pilot Scope & Design User Views Automated Plant Project Scope & Design User Views Lessons & Experiences Questions? Manufacturing Systems Integration at

13. 13 OSI RLink Pilot At Farmingdale Plant Prove OSI PI link to SAP Manual Data entry to OSI PIManual Data entry to OSI PI Automatic interface to SAP via OSI RLinkAutomatic interface to SAP via OSI RLink Ability to analyze data in OSI PIAbility to analyze data in OSI PI

14. 14 BOX To Bulk MASTER BATCH MATERIAL BULK MATERIAL HAND ADD AND COLOR BLEND MATERIAL Two distinct Orders SAP Master Recipe Design Order 1Order 2 Each Order: one operation one phase

15. 15 Standard PSRLink Interface for Informational Data AMAT AMATP01 APHASE AORD APHAR SAP R/3 PP-PI PSRLINK PI Process Instructions Control Recipes SAP PP-PI Process Instructions/Messages

16. 16 AORD - Order Data including start/finish date/time APHASE - Phase Data including External Phases AMAT - Material Allocation Info Raw Material consumption AMATP01 - Material Allocation Info Finished Goods production APHAR - Phase Parameter Blender Batchsize SAP PP-PI Process Instructions/Messages

17. 17 Standard PSRLink Interface for Process Data Request ACONS APROD APHCON ACRST SAP R/3 PP-PI PSRLINK PI Process Instructions Control Recipes Process Messages SAP PP-PI Process Instructions/Messages

18. 18 ACRST - Control Recipe status Start/Processed/Discarded ACONS - Goods Issue Raw Material consumption (MAT_CONS) APROD - Goods Receipt Finished Goods production (MAT_PROD) APHCON - Time Ticket Info Confirmation Qty & Time SAP PP-PI Process Instructions/Messages

19. 19 SAP Order Process Instructions

20. 20 SAP Order Process Instructions in RLink

21. 21 Material Tags (Batch & Qty) Resin Impact Modifier Stabilizer Pigment X Resin1 250# X ImpMod2 150# X Stab3 100# X Pigment4 50# X Resin1 250# X ImpMod2 150# X Stab3 100# X Pigment4 50# X Resin1 230# X ImpMod2 140# X Stab3 110# X Pigment5 60# 1st Conf. Resin1, 250 ImpMod2, 150 Stab3, 100 Pigment4, 50 2nd Conf. Resin1, 480 ImpMod2, 290 Stab3, 210 Pigment4, 50 Pigment5, 60 Phase start Phase confirmation RLink Translation Method Time

22. 22 Manufacturing Integration History Manual Plant pilot Scope & Design User Views Automated Plant Project Scope & Design, Data Views Lessons & Experiences Questions? Manufacturing Systems Integration at

23. 23 Starting Recipe & Phase Process Orders are sorted by Start Date and mimic the ZSCH screen in SAP which is still used to schedule production

24. 24 Blender Production Reporting Enter the correct Batch numbers for all the RM you used with a drop down!

25. 25 Blender Batch Process Data

26. 26 Compound Production Reporting

27. 27 Compound Cont. Process Data You can quickly see process data trends right on the screen

28. 28 User Developed Custom Apps

29. 29 User Developed Custom Apps

30. 30 User Developed Custom Apps

31. 31 Manufacturing Integration History Manual Plant pilot Scope & Design User Views Automated Plant Project Scope & Design, Data Views Lessons & Experiences Questions? Manufacturing Systems Integration at

32. 32 on Vax The Next Step At a Legacy Plant Prove No Process/1 Automatic PCS interface to OSI PI/RLinkAutomatic PCS interface to OSI PI/RLink Proven Auto interface to SAP via OSI RLinkProven Auto interface to SAP via OSI RLink Ability to analyze data in OSI PIAbility to analyze data in OSI PI Interface OSI PI/RLINK with Vax LRM/PRMInterface OSI PI/RLINK with Vax LRM/PRM

33. 33 As-Is Process Model Interfaces SAP LIMS P1PI Provox Model A- PGLRM703 (.SCO,.COM)(Schedule Sequence) A- PGLRM701 (BOM Information) A- PGLRM702 (Campaign Information) A- Vend_lot_val (Valid Vendor Check) B- PGRTR701 (Consumption) B- PGRTR710 / 702 (Production/Finished Goods Adjustment) B- PGRTR706 (Grade Change: P1 & SAP) B- PGRTR711 (Campaign Pending Close) B- PGRTR704 (Campaign Close) B- PGRTR720 (Downtime-Function in SAP) B- PGPCM042 (Inventory Transfer)(.exe) B- PGPCM040 (Inventory Transfer:part of 042) B- PGRTR702 (Production: Part of PGRTR710) B- PGRTR800 (Vendor Lot Modification: Consumption) B- PGRTR716 (MB/CB Reconciliation) AB C D C- PGRTR703 (Submitted by PRM at Campaign Completion) C- PGLIM703 (LIMS Campaign Close) C- PGLIM702 (Sends PMUs to LIMS) D- PGTR705 (LIMS Grading) Process Control PGRTR706 (R-Mail Grade Change) Question: *PGPCM098 (Global Section Backup-BMAT)

34. 34 New Process Model/RLink/SAP Interfaces SAP LIMS PI Provox Model F/A-(Order DownLoad) F/A- PGLRM701 (BOM Information) F/A- PGLRM702 (Campaign Information) B/E- PGRTR701 (Consumption) B/E- PGRTR704 (Campaign Finish) B/E- PGRTR710 (Production) B/I- PGRTR716-(Consumption: 4hr. delay) B/I -PGRTR720 (Line events) B/I- PGRTR706 (Unsolicited: Initial Grade Change: SAP) B/I- PGRTR702 (Finished Goods Adjustment) B- PGPCM042 (Inventory Transfer-SAP/-Rmail to SAP) F/A- PGLRM703 (Schedule Sequence/Order Date Change (TBD)) E = Solicited I = Unsolicited A C D These Are Model and LIMS Specific: C- PGRTR703 (Submitted by PRM at Campaign Completion) C- PGLIM703 (LIMS Campaign Close) C- PGLIM702 (Sends PMUs to LIMS) D- PGTR705 (LIMS Grading) PGPCM098 (Global Section Backup:Model Specific) Process Control E/I F Existing Programs Rlink Server SQL VB B/I

35. 35 BOX To Bulk MASTER BATCH MATERIAL BULK MATERIAL HAND ADD AND COLOR BLEND MATERIAL Mixer Phase Extrusion Phase Packaging Phase Each Order has One Operation SAP Master Recipe Design

36. 36 SAP Order Operations & Phases

37. 37 Standard PSRLink Interface for Informational Data AMAT AMATP01 APHASE AORD SAP R/3 PP-PI PSRLINK PI Process Instructions Control Recipes SAP PP-PI Process Instructions/Messages

38. 38 AORD - Order Data including start/finish date/time, PolyOne ProdVers APHASE - Phase Data including External Phases AMAT - Material Allocation Info Raw Material consumption AMATP01 - Material Allocation Info Finished Goods production SAP PP-PI Process Instructions/Messages

39. 39 Standard PSRLink Interface for Process Data Request ACONS APROD APHCON ACRST SAP R/3 PP-PI PSRLINK PI Process Instructions Control Recipes Process Messages SAP PP-PI Process Instructions/Messages

40. 40 ACRST - Control Recipe status Start/Processed/Discarded ACONS - Goods Issue Raw Material consumption (MAT_CONS) APROD - Goods Receipt Finished Goods production (MAT_PROD) APHCON - Time Ticket Info Confirmation Qty & Time SAP PP-PI Process Instructions/Messages

41. 41 SAP Order Process Instructions

42. 42 SAP Order Process Instr Characteristics

43. 43 SAP Order Process Instructions in RLink

44. 44 SAP Order Bill of Materials in RLink

45. 45 Tags Recipe Matl Batch Qty X Rcp1 Resin Resin1 250# X Rcp1 ImpMod ImpMod2 150# X Rcp1 Stab Stab3 100# X Rcp1 Pigment Pigment4 50# X Rcp1 Resin Resin1 250# X Rcp1 ImpMod ImpMod2 150# X Rcp1 Stab Stab3 100# X Rcp1 Pigment Pigment4 50# X Rcp1 Resin Resin1 230# X Rcp1 ImpMod ImpMod2 140# X Rcp1 Stab Stab3 110# X Rcp1 Pigment Pigment5 60# 1st Conf. Rcp1Rcp1Rcp1Rcp1 ResinImpModStabPigment Resin1ImpMod2Stab3Pigment4 250 15010050 Phase start Phase confirmation Tags Recipe Matl Batch Qty 2nd Conf. Rcp1Rcp1Rcp1Rcp1Rcp1 ResinImpModStabPigmentPigment Resin1ImpMod2Stab3Pigment4Pigment5 4802902105060 RLink Translation Method Time

46. 46 RLink Interface data in PI

47. 47 RLink Interface data in PI

48. 48 RLink Interface data in PI

49. 49 Standard PSRLink Interface for Unsolicited Process Data ACONS APROD MATRANS1 MATRANS2 LINEVENT SAP R/3 PP-PI PSRLINK PI SAP PP-PI Process Instructions/Messages Process Messages

50. 50 PI_CONS - Unsolicited CONS unplanned consumption (SAP_TRAN) PI_PROD - Unsolicited PROD unplanned production (SAP_TRAN) MATRANS1 - FG Grading Move from QI, then Batch ID change MATRANS2 - Rework CONS Move from Blocked, then CONS LINEVENT - Line Events Populates custom SAP table SAP PP-PI Process Instructions/Messages

51. 51 RLink Interface data in PI

52. 52 RLink Alarming via PI tags

53. 53 Manufacturing Integration History Manual Plant pilot Scope & Design User Views Automated Plant Project Scope & Design, Data Views Lessons & Experiences Questions? Manufacturing Systems Integration at

54. 54 Manufacturing Integration History Manual Plant pilot Scope & Design User Views Automated Plant Project Scope & Design, Data Views Lessons & Experiences Questions? Manufacturing Systems Integration at