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Power Generation May, 02 Slide 1 SIEMENS POWER GENERATION – Phil Scotson.

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Presentation on theme: "Power Generation May, 02 Slide 1 SIEMENS POWER GENERATION – Phil Scotson."— Presentation transcript:

1 Power Generation May, 02 Slide 1 SIEMENS POWER GENERATION – Phil Scotson

2 Power Generation June 04 Slide 2 Presentation structure Company background ERP system background Scope of use – defining the interfaces Interfaces in detail Conclusion

3 Power Generation June 04 Slide 3 Stand: Managing Board Regional organization: Regional Offices; Regional Companies, Representative Offices, agencies Power Automation and Control Automation and Drives (A&D) Industrial Solutions- and Services (I&S) Siemens Dematic AG (SD) Siemens Building Technologies AG (SBT) Information and Communication Networks (ICN) Information and Communication Information and Communication Mobile (ICM) Siemens Business Services GmbH & Co. OHG (SBS) Transportation Systems (TS) Transportation Siemens VDO Automotive AG (SV) Osram GmbH Lighting Siemens Financial Services GmbH (SFS) Finance and Real Estate Medical Solutions (Med) Medical Power Generation (PG) Power Transmission and Distribution (PTD) Siemens Real Estate (SRE) The Organizational Structure of Siemens Business Segments and Groups Siemens at a Glance Siemens PG Profile Siemens PG Key Figures

4 Power Generation June 04 Slide 4 Siemens Power Generation: 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 Portrait Siemens at a Glance Siemens PG Profile Siemens PG Key Figures

5 Power Generation June 04 Slide 5 Main Office Block Machining Facilities Blade Manufacture Balancing Facilities Generator Repair C.A. Parsons Works

6 Power Generation June 04 Slide 6 CA Parsons Works - Facts and Figures Circa 700 personnel Site covers 170,000 m 2 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 Power Generation June 04 Slide 7 First Turbine Driven Ship 1897 First Turbine Driven Generator 1884 First 50 MW Turbine 1922 First Industrial GT in UK 1945 First Nuclear Power Station 1953 First 500 MW Cross Compound Turbine First 660 MW Turbine in UK 1986 First Condensing Turbine 1891 Sir Charles Parsons Founded Parsons Works 1889

8 Power Generation June 04 Slide 8 Large complex parts eg Casings and Rotors

9 Power Generation June 04 Slide 9 Heavy Machining 80 CNC Machine Tools 170,000M 2 Covered area Cranage up to 300 tonnes Over 12,000 Man Years of Experience All Major design types worked on Generator Rotors Turbine Assembly Blade Manufacture Production Facilities

10 Power Generation June 04 Slide 10 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 Services to the Power Industry

11 Power Generation June 04 Slide 11 Customers – Power Station owners SPG History SPG at a Glance SPG Capabilities SPG Customers & References

12 Power Generation May, 02 Slide 12 ERP System background

13 Power Generation June 04 Slide 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 Power Generation June 04 Slide 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 Power Generation June 04 Slide 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 Power Generation June 04 Slide 16 Sample Avante GUI screen

17 Power Generation June 04 Slide 17 The extent of Avanté

18 Power Generation June 04 Slide 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 Power Generation June 04 Slide 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 Power Generation June 04 Slide 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 Power Generation June 04 Slide 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 Power Generation June 04 Slide 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 Power Generation June 04 Slide 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 Power Generation June 04 Slide 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 Power Generation June 04 Slide 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 Power Generation June 04 Slide 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 Power Generation June 04 Slide 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 Power Generation June 04 Slide 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 Power Generation June 04 Slide 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 Power Generation June 04 Slide 30 The End Any Questions

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