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WE HELP YOU INVENT THE FUTURE. TM

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Presentation on theme: "WE HELP YOU INVENT THE FUTURE. TM"— Presentation transcript:

1 WE HELP YOU INVENT THE FUTURE. TM

2 WE HELP YOU INVENT THE FUTURE. TM Today Presentation Who we are Who we are SAP Architecture SAP Architecture MES Architecture MES Architecture SAP R/3 PPPI Rlink Implementations SAP R/3 PPPI Rlink Implementations Integration Specification Integration Specification Whats next Whats next

3 WE HELP YOU INVENT THE FUTURE. TM Dow Corning Corporation World leader in silicon technology World leader in silicon technology Formed in 1943 in Midland, Michigan Formed in 1943 in Midland, Michigan Company shares are equally owned by The Dow Chemical Company and Corning Incorporated Company shares are equally owned by The Dow Chemical Company and Corning Incorporated Over 5,000 products Over 5,000 products Over 45,000 customers worldwide Over 45,000 customers worldwide 60% of business outside the U.S. 60% of business outside the U.S. Sales of $2.6 billion Sales of $2.6 billion Over 9,000 employees worldwide Over 9,000 employees worldwide

4 WE HELP YOU INVENT THE FUTURE. TM Dow Corning Industries Aerospace Aerospace Automotive Automotive Chemicals/ Petrochemicals Chemicals/ Petrochemicals Construction Construction Consumer Products Consumer Products Electrical/Electronics Electrical/Electronics Food Processing Food Processing Industrial Maintenance & Production Industrial Maintenance & Production Medical Products Medical Products Paint & Coatings Paint & Coatings Personal, Household & Automotive Care Personal, Household & Automotive Care Pharmaceuticals Pharmaceuticals Plastics Plastics Pressure-Sensitive Adhesives Pressure-Sensitive Adhesives Textiles & Leather Textiles & Leather

5 WE HELP YOU INVENT THE FUTURE. TM SAP R/3 ARCHITECTURE

6 WE HELP YOU INVENT THE FUTURE. TM SAP R/3 ARCHITECTURE CORE SAP R/3 Release 4.6b SD, MM, PP, FI, CO, QM, IM, WM,PM,AA, AP, AR, Product Cost CORE SAP R/3 Release 4.6b SD, MM, PP, FI, CO, QM, IM, WM,PM,AA, AP, AR, Product Cost EHS SAP R/3 Release 3.0f/2.2b Material Safety EHS SAP R/3 Release 3.0f/2.2b Material Safety APO SAP R/3 Release 4.6a/2.0a Advanced Planning & Scheduling APO SAP R/3 Release 4.6a/2.0a Advanced Planning & Scheduling BW SAP R/3 Release 4.6c/2.0b Advanced Planning & Scheduling BW SAP R/3 Release 4.6c/2.0b Advanced Planning & Scheduling CRM SAP R/3 Release 4.6a/2.0b Customer Relation- Ship Mgmt CRM SAP R/3 Release 4.6a/2.0b Customer Relation- Ship Mgmt ESS/ITS SAP R/3 Release 2.0 Employee Self Service ESS/ITS SAP R/3 Release 2.0 Employee Self Service Global Data Warehouse(GDW) Documentum – Document imaging Global ADC(Barcoding) Global EDI – Harbinger ADP – U.S. Payroll Extranet Order Status – Haht Jetform – Document printing Commerce Path – Document faxing LIMS – Sample Manager OSI-Rlink US Sales & Use Tax – Vertex Luminate – R/3 performance monitor Patrol - R/3 performance data and alert management LP Plus – Print Server Mgmt. Data & Document image Archiving – IXOS Global Data Warehouse(GDW) Documentum – Document imaging Global ADC(Barcoding) Global EDI – Harbinger ADP – U.S. Payroll Extranet Order Status – Haht Jetform – Document printing Commerce Path – Document faxing LIMS – Sample Manager OSI-Rlink US Sales & Use Tax – Vertex Luminate – R/3 performance monitor Patrol - R/3 performance data and alert management LP Plus – Print Server Mgmt. Data & Document image Archiving – IXOS Brazil LSA SAP R/3 Release 3.0f Brazil Brazil LSA SAP R/3 Release 3.0f Brazil DCC ABAP Programs DCC ABAP Applications] DCC ABAP Reports User Exits Batch Jobs Variants DCC ABAP Programs DCC ABAP Applications] DCC ABAP Reports User Exits Batch Jobs Variants users 9 Languages 90+ locations users 9 Languages 90+ locations 100+ users 35 users 300 planned 35 users 300 planned 80+ users Planned 80+ users Planned users Planned users Planned Bolt-ons/Interfaces ALE RFC ATP BAPI

7 WE HELP YOU INVENT THE FUTURE. TM SAP R/3 IMPLEMENATION STATUS 9000 users 9000 users 1400 to 1500 concurrent users 1400 to 1500 concurrent users 1100 double byte users 1100 double byte users 24 X 7 operations (3 hours - Sunday Morning maintenance) 24 X 7 operations (3 hours - Sunday Morning maintenance) 52 DC Legal Entities on SAP 52 DC Legal Entities on SAP 110 SAP Plants(sites) on SAP 110 SAP Plants(sites) on SAP 28 Manufacturing Plants 28 Manufacturing Plants 28 Warehousing & Distribution Sites 28 Warehousing & Distribution Sites 50,000+ Materials(Raw Materials-ROH & Intermediates- HALB) 50,000+ Materials(Raw Materials-ROH & Intermediates- HALB) 80,000+ MRO Materials(ERSA,NLAG) 80,000+ MRO Materials(ERSA,NLAG) 60,000+ Customers 60,000+ Customers

8 WE HELP YOU INVENT THE FUTURE. TM SAP MODULES Demand Planning, Supply Network Planning APO Product cost reporting, Global Sales Finance reporting, DSI BW Material Safety Data Sheets EHS ORG, PAD, TIM, TRV, PAY, INT HR Certs, Insp Planning, Q-notifications, RR QM SOP, MRP, MPS, SFC, IS, PC, CRP, SYS, PP/PI PP Maint Ord, Equip BOM, Preventive Maint PM Sales, Shipping, Transp, Billing, Pricing,Credit SD PUR, IS, WM, IM, IV MM Inv Ctrl, Asset Acctng AM Cost Ctr, Ord & Proj, Prod Cost, PA, PCA CO AP, AR, GL, SL, AA FI

9 WE HELP YOU INVENT THE FUTURE. TMCountries Implementations covering 19 localized countries: Implementations covering 19 localized countries: AMERICASASIAEUROPE USAustraliaBelgium MexicoHong KongUK CanadaNew ZealandItaly BrazilMalaysiaFrance TaiwanSpain JapanGermany China (Others: Poland, Sweden, Thailand Austria) Korea Singapore (Others: Indonesia, Philippines, India)

10 WE HELP YOU INVENT THE FUTURE. TM Manufacturing Systems Team Mission: Provide and support total solutions that optimize the product delivery business processes. Team Mission: Provide and support total solutions that optimize the product delivery business processes. Teams Product and Services: Application Systems and I/T expertise Teams Product and Services: Application Systems and I/T expertise

11 WE HELP YOU INVENT THE FUTURE. TM ADC (Bar-coding) - Functionality ADC (Bar-coding) - Functionality –Inventory Accuracy Improvement –Automated Transactions for IM and WM modules –Operator entry of data for IM and WM transactions MES - Inventory and Delivery

12 WE HELP YOU INVENT THE FUTURE. TM MES - Inventory and Delivery Labeling Functionality (Americas only) Labeling Functionality (Americas only) –Provide for Label design –Provide integration of SAP information onto product label –Provide Print and Apply for labeling of materials on the plant floor

13 WE HELP YOU INVENT THE FUTURE. TM MES - Quality Management Quality Management Quality Management Laboratory Information Management (LIMS) - Manage Sample tracking and test results for Quality Assurance and Analytical laboratoriesLaboratory Information Management (LIMS) - Manage Sample tracking and test results for Quality Assurance and Analytical laboratories Provide automated interfaces to SAP for the QM ModuleProvide automated interfaces to SAP for the QM Module Provide automated interfaces to laboratory instruments (Gas Chromatography, Viscometers, etc.)Provide automated interfaces to laboratory instruments (Gas Chromatography, Viscometers, etc.)

14 WE HELP YOU INVENT THE FUTURE. TM OSIsoft PI System – OSIsoft PI System – –Collects all data from the process control systems –Collects manually entered data –Provides a tool set for analyzing the data –Interface to SAP for activity and inventory transactions MES - Production Execution

15 WE HELP YOU INVENT THE FUTURE. TM Global systems – Global systems – –ADC - 8 servers serving 13 sites– 3500 users –PI – 8 servers serving 13 sites – 650 users –LIMS – 7 servers serving 13 sites – 1200 users –Totals – 23 servers –>5000 users – 3 major apps Other – Americas Labeling, SAP interfaces, Lab instrument interfaces, Safety Systems, etc. Other – Americas Labeling, SAP interfaces, Lab instrument interfaces, Safety Systems, etc. MES - Summary

16 WE HELP YOU INVENT THE FUTURE. TM SAP-PCS Integration Team Improve the effectiveness of the application of SAP Business Process Workflow across Dow Corning manufacturing sites. Ensure that the Manufacturing & Production operational information is appropriately integrated with the supply chain and business process workflow. Improve the effectiveness of the application of SAP Business Process Workflow across Dow Corning manufacturing sites. Ensure that the Manufacturing & Production operational information is appropriately integrated with the supply chain and business process workflow.

17 WE HELP YOU INVENT THE FUTURE. TM Efficient Manufacturing Transactions Efficient Manufacturing Transactions –through automated routine tasks and coordinated activities through better communications. Integrated Processes Integrated Processes –vertically linking production within the manufacturing processes. Integrated Information Systems Integrated Information Systems –allowing for improved management decision making through measured and monitored quality and cost control. Reduced Product Variability Reduced Product Variability –in manufacturing, produce a specific material one way and only one way. Business Drivers

18 WE HELP YOU INVENT THE FUTURE. TM What to Integrate COSTING FORECASTING PURCHASING INVENTORY MANAGEMENT HUMAN RESOURCES SCHEDULING ORDER MANAGEMENT FINANCIALS PRODUCT DEFINITION ENTERPRISE SAP R/3 QUALITY MANAGEMENT DOCUMENT CONTROL MATERIAL USAGE PRODUCT TRACKING PRODUCTION HISTORY RESOURCES MAINTENANCE MANAGEMENT PROCESS ANALYSIS PRODUCTION DISPATCHING FACTORY FLOOR MES PRODUCT DEMAND, BILL OF MATERIAL RECIPE, FORMULATION, RESOURCES, LABOR, INVENTORY STATUS, WORK INSTRUCTIONS ORDER STATUS,COMPLETIONS, START/STOP TIMES, RESOURCE, LABOR, MATERIAL STATUS, ACTUAL BILL OF MATERIAL, PRODUCTION QUALITY DATA, SCRAP, WASTE

19 WE HELP YOU INVENT THE FUTURE. TM Integration Architecture Rlink PROCESS INFORMATION SYSTEM REAL TIME DATABASE HISTORIAN PI - BATCH CALCULATION ENGINE S P C MANUAL INPUT DCS SCADA LIMS SAP R/3 SYSTEM PP-PIPMQM NETWORK

20 WE HELP YOU INVENT THE FUTURE. TM Production Information Flow Goods Issue –Material Number –Actual Quantity –Operation/Phase –etc. Goods Receipt –Material Number –Actual Quantity –Operation/Phase –etc. Process Control –Key Process Information –Operation/Phase –Test Reduction / Parametric Acceptance –Process Variability Schedule Information –Process Order/Batch Number –Resource –Proposed Quantity –etc. Rlink Layer

21 WE HELP YOU INVENT THE FUTURE. TM Integration Goals Automate production recordingAutomate production recording Improve Data AccuracyImprove Data Accuracy Improve timeliness of data reportingImprove timeliness of data reporting Eliminate Production RecordersEliminate Production Recorders Reconcile physical and SAP inventory automaticallyReconcile physical and SAP inventory automatically Reduce Cost VariancesReduce Cost Variances E-Commerce supportE-Commerce support

22 WE HELP YOU INVENT THE FUTURE. TM Integration Scenarios DCS = Source of Data.DCS = Source of Data. 1.Continuous Processes. 2.Trailer Moves. 3.Mass Balance. 4.Batch Processes 5.Material movements

23 WE HELP YOU INVENT THE FUTURE. TM Integration need Dow Corning Manufacturing Engineer comment: " Being able to automatically download information from I-Batch to SAP would benefit us tremendously. We are operating 25 minute batches which translates into 57 batches/day. This would require (57 per material) SAP transactions to write off these raw materials for each batch. We cannot afford to have our operators spending this type of time away from running the process. What can you do to help with this issue? (This will be a common issue for every future I-batch application implemented)...

24 WE HELP YOU INVENT THE FUTURE. TM OSI Rlink Targets –Continuous processes for PO duration set start date and timefor PO duration set start date and time for reporting interval set as shift, day, hour, etc.for reporting interval set as shift, day, hour, etc. –Batch processes w/out Batch Engine PI-ProcessBook/VB applications as campaign managerPI-ProcessBook/VB applications as campaign manager –Batch processes with Batch Engine Foxboro IA Batch, Intellution iBatchFoxboro IA Batch, Intellution iBatch

25 WE HELP YOU INVENT THE FUTURE. TM

26 Procedure to Reconcile Physical Inventory and SAP Inventory Automatically.

27 WE HELP YOU INVENT THE FUTURE. TM

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32 Integration Specification Makes Manufacturing document... Makes Manufacturing document... –what their process is –what parameters need to be captured for the Business System and Business Recipe development

33 WE HELP YOU INVENT THE FUTURE. TM Integration Specification for each process

34 WE HELP YOU INVENT THE FUTURE. TM

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36 Integration Skills for Integration

37 WE HELP YOU INVENT THE FUTURE. TM Whats next? Whats next?

38 WE HELP YOU INVENT THE FUTURE. TM OSI Rlink Robust Robust Reliable Reliable Powerful Powerful Flexible Flexible Perfect fit Perfect fit Always works!!! Always works!!!


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