1. SIEMENS POWER GENERATION – Phil Scotson

2. Presentation structure
Company background
ERP system background
Scope of use – defining the interfaces
Interfaces in detail
Conclusion

3. The Organizational Structure of Siemens Business Segments and Groups
Managing Board
Siemens at a Glance
Siemens PG Profile
Siemens PG Key Figures
Power
Information and Communication
Medical
Power Generation (PG)
Information and Communication Networks (ICN)
Medical Solutions (Med)
Power Transmission and
Distribution (PTD)
Information and Communication Mobile (ICM)
Lighting
Automation and Control
Siemens Business Services GmbH & Co. OHG (SBS)
Osram GmbH
Automation and Drives (A&D)
Transportation
Finance and Real Estate
Industrial Solutions- and
Services (I&S)
Siemens Financial Services GmbH
(SFS)
Siemens Dematic AG (SD)
Transportation Systems (TS)
Siemens Building Technologies AG (SBT)
Siemens VDO Automotive AG (SV)
Siemens Real Estate (SRE)
Stand:
Regional organization: Regional Offices; Regional Companies, Representative Offices, agencies

4. Portrait Siemens Power Generation: Siemens at a Glance
Siemens PG Profile
Siemens PG Key Figures
A strong number 2 ranking in the global power plant market
Concentration on fossil-fuelled power generation technology, components, systems and power plants
Expertise in power plant and system services
Long-term operation and maintenance (O&M) agreements
Leading vendor of industrial applications
Successful integration of the fossil division of Westinghouse
Innovation and technical advancement
Power Generation

5. C.A. Parsons Works Balancing Facilities Generator Repair
Blade Manufacture
Main Office Block
Machining Facilities

6. CA Parsons Works - Facts and Figures
Circa 700 personnel
Site covers 170,000 m2
OEM Status for over 60,000 MW of plant
Fleet in over 32 Countries Worldwide
Over 100 years on the site $
Turnover in excess of $100 million

7. Sir Charles Parsons Founded Parsons Works 1889
First Turbine Driven Generator
1884
Sir Charles Parsons
Founded Parsons Works 1889
First 660 MW Turbine in UK
1986
First Turbine Driven Ship
1897
First 500 MW Cross Compound
Turbine -1961
First Condensing Turbine
1891
First 50 MW Turbine
1922
First Industrial GT in UK
1945
First Nuclear Power Station
1953

8. Large complex parts eg Casings and Rotors

9. Production Facilities
80 CNC Machine Tools
170,000M2 Covered area
Cranage up to 300 tonnes
Over 12,000 Man Years of Experience
All Major design types worked on
Heavy Machining
Turbine Assembly
Generator Rotors
Blade Manufacture

10. Services to the Power Industry
On-Site Maintenance Services
Site Management
Commissioning
Dynamic Balancing
In-Situ Machining
NDT
Technical and Operational Support
Design Consultancy
Metallurgical Services
Technical Advice
Spares and Repairs
Outage Related
Strategic
Breakdown
Retrofits
Efficiency Improvements
Life Extension and Integrity
Maintainability Improvements
Latest Technology

11. Customers – Power Station owners
SPG History
SPG at a Glance
SPG Capabilities
SPG Customers & References

12. ERP System background

13. ERP Implementation plan
Steering group, Reps from all business functional areas
Evaluation process
Change business processes
Big bang implementation
Best fit for business - at the time !

14. ERP Project Aims - Integrated Business System
Improve planning systems
Better ability to accurately predict, therefore to manage the business
Question and change our working practices as required
Single / correct way of operation (only one version of the truth)
Consistency and complete data
No islands of information
Reduce multiple data entry / increased reuse of data
Single user interface (expert in 1 system)
Get off obsolete / unmaintained databases & hardware
To keep our Business Systems up to date with evolving technology
GUI, potential for E-business

15. Avante ERP Technical details
Avante from software company Epicor
U2 – Unidata PICK database - multivalue, transactional based
120 concurrent user licence.
Multi processor server, 4 Pentium4, 2Gb memory, RAID discs
Live account = MBytes

16. Sample Avante GUI screen

17. The extent of Avanté

18. Scope of ERP use – therefore integrated
Quotations & Sales Order acknowledgements
Order BOM configurations
Material Control
Purchasing, MRP & buy to order
Quality Control, Stock control, Tool mgt
Manufacturing
Work order routings, progress status
Lead time Planning, + feeding details for finite scheduling
Change control & Locking
Project / order management
Costing – standard, budget, actual hours & costs
Shipping / despatch control
Financial control
Supplier invoices, payments, cash mgt
Sales invoices
All official company external documents

19. Out of scope – therefore interfaces to other systems
Engineering – to & from in-house PDM system, future – global PDM
SFDC – to & from in-house timelines, clock card system
Site Operations – to & from in-house system
Payroll / personnel – to & from
APS – Advanced Planning System – finite scheduling module
NB. Non to customers / suppliers via Ebiz

20. Why out of scope ? Forced Working within a Global company
Helping implementation, practicalities
By design, optimum use
Better ‘external’ software solution eg APS
External process eg payroll

21. Engineering PDM System interface
In-house PDM simulates future global Siemens solution
To Engineering
Order MBOM configurations
Generic components, required dates & priority order
Changes to dates, emerging extent of supply
From Engineering
Order EBOM configurations
Specific items (parts) with all associated attributes
Changes to items & drawings
Polling for data, every minute
Token codes dictate process

22. Shop Floor Data Capture interface
To SFDC
Work order operation routings – what to make, when, on what machines
Changes
From SFDC
Progress status
Timelines, hours taken
Clock cards, overtime & shifts
Polling for data, every minute
Token codes dictate process
Batch ASCII files manually invoked, schedule time

23. Other interfaces Site Operations
To Site Ops - Work order routings – for source
From Site Ops - Timelines, clock cards
Payroll
To Payroll - Overtime & Shifts
From Payroll - Full payroll costs into Financial journals
Personnel
From Personnel - New starters, leavers, movements
APS – Manufacturing Finite scheduling key resources
To APS – outstanding work, estimated hours, earliest start dates
From APS – priority work lists, expected completion dates

24. How the interfaces work
Polling, auto running 24x7
Every minute searching for a file on network drive
First section of each line is a token code
Each code calls specific interface process or simulates a manual menu process
Batch file updates, scheduled day & time or manually control when run
Each line predefined format, usually csv
Error files log any problems
Simulating manual processes, same validations as for users
Populate database records directly
Archive copies held to enable re-runs

25. Positive aspects Allows split between global & local business systems
Eg global PDM Engineering & local ERP
Allows phased implementations, avoids too much of a big bang
Functionality not yet available, training users
Eg SFDC
Out of scope of the ERP system
Better specialist software used for specific tasks
Eg APS finite scheduling & its what-if scenarios
Remote users, not on network
Eg Site Power Stations

26. Negative aspects Cost of developing
Specification, writing, testing all envisaged permutations
Delays on implementation time schedules
Not moving off legacy systems, not a clean break
Extra links in information chains, PC – Unix, debugging
Ongoing maintenance costs
External bespoke software support
Internal system support

27. Negative example - Avante / PDM interface
Not originally envisaged
Global initiative, optimistic time scales for availability
Costs (man hours)
Internal – defining functional specification, testing
External – detail system spec, writing software
100 k but capped !
Delay whole ERP implementation project plan - 8 months
Originally planned (optimistically) 9 months (Oct 99 – July 00)
Actual project time 17 months – live in Mar 01

28. Future interfaces - XML
Standardised approach
Predefined, standard format of files
Simulates manual menu screen process
Mapping of XML fields to process fields (screen variables)
Designed for Ebiz but wider application
Off the shelf interface solutions !?!??

29. Conclusion Overview of the Avante ERP system at SPG
Large traditional manufacturing industry, global organisation
Other systems - existing, legacy, global, external
Reasons for interfaces to & from ERP
Details on the interfaces
Positive aspects
Negative aspects
But usually critical, KIS - Keep It Simple

30. The End
Any
Questions