Manufacturing
Systems
Integration at
1
MA Hanna Yesterday

Headquartered in Cleveland, Ohio



Resin Distribution


$ 483 million
Plastics Compounding


$ 529 million
Color Compounding


$ 460 million
Rubber Compounding


Employs 7,000 people worldwide
$2.3 Billion in Sales - 1999
$ 437 million
Shapes

$ 391 million
2
Geon Yesterday

Headquartered in Avon Lake, Ohio


World’s largest producer of vinyl (PVC)
compounds


$ 235 million
Engineered Films


$ 820 Million
North America’s largest producer of dispersion
resins & formulators


Employs 3,100 people worldwide
$ 215 million
Joint Venture with OxyChem (OxyVinyls) &
various joint ventures worldwide
3
Strategy
P
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s
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m
b
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r
P
R
O
C
E
S
S
O
R
S
Service &
Distribution
4
Building Materials
Automotive
Appliances &
Business Equipment
Packaging
Packaging
Consumer
Consumer
Products
Products
Communications/
Electronics
C
o
n
s
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m
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r
s
Manufacturing Systems Integration at
Manufacturing Integration History
Manual Plant pilot
•Scope & Design
•User Views
Automated Plant Project
•Scope & Design, Data Views
Lessons & Experiences
Questions?
5
In 1988, we began our Computer Integrated
Enterprise vision by attempting to simplify,
automate and integrate our internal processes
Supplier(s)
Order Processing
Sell-Service

Manufacturing
Design-Make
Procurement
Source
Order
Fulfillment
Logistics-Delivery
Receive
Payment
Close Sale
This initiative was focused in large part on our compound
manufacturing assets and product line.
6
Customer(s)
Planning
Geon’s Computing Environment
Order Entry
System
SID
Corporate
Financial
System
NT
Procurement
Raw Material
Inventory
System
Forecasting/
Planning
System
FG / Shipping
System
Planning
GENERAL STORE
Distribution
Plant
CHAMPS
Inventory
Management
Manufacturing
Execution
System (MES) PROCESS/1
LIMS
Process Model
(SCADA)
Line
Run Tracking
Process Control
7
High Level Information Flow
PREPARE FOR
PRODUCTION
RUNS
INPUTS
KEY
FUNCTIONS
EXECUTE
PRODUCTION
RUNS
OUTPUTS/
INPUTS
PREPARE LINE
RECIPE
PACKET
MATERIAL
DELIVERIES
PRODUCTION
SCHEDULE/
BOM
ORDER,
RECEIVE, AND
BAR-CODE
MATERIALS
PICK RAW
MATERIALS FOR
3RD & 4TH
FLOOR
LOT SPECIFIC
RECIPE PACKET
MAKE-UP BULK,
MASTER BATCH
AND HAND-ADD
MATERIALS
SET UP SPC
SPECS
SPC/SQC ANALYSIS
RESULTS
KEY
FUNCTIONS
BAR-CODED
RAW
MATERIALS
SPC SPECS
EXECUTE,
CONTROL, AND
MONITOR RUN
ANALYZE
PRODUCTION
RESULTS
OUTPUTS/
INPUTS
RUN HISTORY:
•PRODUCTION
RUN AUDIT
TRAIL
•MATERIAL
USAGE
•FINISHED
GOODS
PRODUCTION
•RUN
START/STOP
TIMES
RECIPE ADJUSTMENTS
8
OUTPUTS
MATERIAL
PERFORMANCE
VIEW/UPDATE
ANALYZE RUN
PERFORMANCE
PERFORM SQC
ANALYSIS
RUN
PERFORMANCE
MEASURES
PRODUCTION
RUN AUDIT
TRAIL
•DOWNTIME
EVENTS
•SALVAGE
TRACK ACTUAL
RUN
PERFORMANCE
KEY
FUNCTIONS
•PROCESS
VARIABLES
SPC/SQC ANALYSIS
RESULTS
The Manufacturing Systems Journey
INCREASE QUALITY
AND CONSISTENCY
SIMPLIFICATION
PREPARE
PRODUCTION
RUNS
EXECUTE
PRODUCTION
RUNS
CONTINUOUS
IMPROVEMENT
COMPETITIVE
COSTS
ANALYZE
PRODUCTION
RUNS
9
CUSTOMER
RESPONSIVENESS
Mfg. Systems Strategy Study
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
All Geon Sites
Corporate
•
•
•
•
• EPM
• P1
SAP
DW
• EIS
• MDS
• Other
Data Acquisition
standard data acquisition approach
standard data elements
standard data structure
Manual data capture where controller data feeds
unavailable
Plant
•
•
•
•
MDS
LRM/PRM
OSI PI
Line Recipe Management
• LRM capability extended to plants where it does
not exist
• PRM can be supported with more common skills
Process Ctl
10
MDE
• DA
• DH/DHE
• SQC
Mfg. Systems Strategy Study
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
11
Manufacturing Systems Integration at
Manufacturing Integration History
Manual Plant pilot
•Scope & Design
•User Views
Automated Plant Project
•Scope & Design
•User Views
Lessons & Experiences
Questions?
12
OSI RLink Pilot
At Farmingdale Plant
Prove OSI PI link to SAP
All Geon Sites
• EPM
• P1
Plant
•Automatic interface to
SAP via OSI RLink
Corporate
•Manual Data
entry to OSI PI
SAP
DW
• EIS
• MDS
• Other
MDS
LRM/PRM
•Ability to analyze
data in OSI PI
OSI PI
Process Ctl
13
MDE
• DA
• DH/DHE
• SQC
SAP Master Recipe Design
MASTER BATCH MATERIAL
Two distinct Orders
BULK MATERIAL
HAND ADD
AND
COLOR BLEND
MATERIAL
Order 1
Order 2
Each Order:
•one operation
•one phase
BOX
14
To Bulk
SAP PP-PI Process Instructions/Messages
SAP R/3
PP-PI
Process
Instructions
Control Recipes
PSRLINK
PI
15
SAP PP-PI Process Instructions/Messages

AORD - Order Data


APHASE - Phase Data


Raw Material consumption
AMATP01 - Material Allocation Info


including External Phases
AMAT - Material Allocation Info


including start/finish date/time
Finished Goods production
APHAR - Phase Parameter

Blender Batchsize
16
SAP PP-PI Process Instructions/Messages
SAP R/3
PP-PI
Process Messages
Process
Instructions
Control Recipes
PSRLINK
PI
17
SAP PP-PI Process Instructions/Messages

ACRST - Control Recipe status


ACONS - Goods Issue


Raw Material consumption (MAT_CONS)
APROD - Goods Receipt


Start/Processed/Discarded
Finished Goods production (MAT_PROD)
APHCON - Time Ticket Info

Confirmation Qty & Time
18
SAP Order Process Instructions
19
SAP Order Process Instructions in RLink
20
RLink Translation Method
X Resin1 250#
X Resin1 250#
X Resin1 230#
X ImpMod2 150#
X ImpMod2 150#
X ImpMod2 140#
X Stab3 100#
X Stab3 100#
X Stab3 110#
X Pigment5 60#
X Pigment4 50#
Phase start
X Pigment4 50#
Phase confirmation
Phase confirmation
Time
Material Tags (Batch & Qty)
•Resin
•Impact Modifier
•Stabilizer
•Pigment
1st Conf.
Resin1, 250
ImpMod2, 150
Stab3, 100
Pigment4, 50
21
2nd Conf.
Resin1, 480
ImpMod2, 290
Stab3, 210
Pigment4, 50
Pigment5, 60
Manufacturing Systems Integration at
Manufacturing Integration History
Manual Plant pilot
•Scope & Design
•User Views
Automated Plant Project
•Scope & Design, Data Views
Lessons & Experiences
Questions?
22
Starting Recipe & Phase
Process Orders are sorted by
Start Date and mimic the ZSCH screen in SAP which
is still used to schedule production
23
Blender Production Reporting
Enter the correct Batch numbers for
all the RM you used with a drop down!
24
Blender Batch Process Data
25
Compound Production Reporting
26
Compound Cont. Process Data
You can quickly see process data
trends right on the screen
27
User Developed Custom Apps
28
User Developed Custom Apps
29
User Developed Custom Apps
30
Manufacturing Systems Integration at
Manufacturing Integration History
Manual Plant pilot
•Scope & Design
•User Views
Automated Plant Project
•Scope & Design, Data Views
Lessons & Experiences
Questions?
31
The Next Step
At a Legacy Plant
Prove No Process/1
•Automatic PCS interface
to OSI PI/RLink
• EPM
• P1
Plant
•Interface OSI PI/RLINK
with Vax LRM/PRM
All Geon Sites
Corporate
•Proven Auto interface
to SAP via OSI RLink
SAP
DW
• EIS
• MDS
• Other
MDS
LRM/PRM
on Vax
•Ability to analyze
data in OSI PI
Process Ctl
32
OSI PI
MDE
• DA
• DH/DHE
• SQC
As-Is Process Model Interfaces
A- PGLRM703 (.SCO,.COM)(Schedule Sequence)
A- PGLRM701 (BOM Information)
A- PGLRM702 (Campaign Information)
A- Vend_lot_val (Valid Vendor Check)
B- PGRTR701 (Consumption)
SAP
B- PGRTR710 / 702 (Production/Finished Goods
Adjustment)
B- PGRTR706 (Grade Change: P1 & SAP)
PGRTR706 (R-Mail Grade Change)
B- PGRTR711 (Campaign Pending Close)
B- PGRTR704 (Campaign Close)
B- PGRTR720 (Downtime-Function in SAP)
B- PGPCM042 (Inventory Transfer)(.exe)
P1
B- PGPCM040 (Inventory Transfer:part of 042)
PI
B- PGRTR702 (Production: Part of PGRTR710)
B- PGRTR800 (Vendor Lot Modification:
Consumption)
A
B- PGRTR716 (MB/CB Reconciliation)
B
C
LIMS
Model
D
C- PGRTR703 (Submitted by PRM at
Campaign Completion)
C- PGLIM703 (LIMS Campaign Close)
C- PGLIM702 (Sends PMU’s to LIMS)
Process Control
Question:
*PGPCM098 (Global
Section Backup-BMAT)
D- PGTR705 (LIMS Grading)
33
Provox
New Process Model/RLink/SAP Interfaces
F/A-(Order DownLoad)
F/A- PGLRM701 (BOM Information)
F/A- PGLRM702 (Campaign Information)
B/E- PGRTR701 (Consumption)
SAP
B/E- PGRTR704 (Campaign Finish)
B/E- PGRTR710 (Production)
B/I- PGRTR716-(Consumption: 4hr. delay)
B/I -PGRTR720 (Line events)
E/I
F
B/I- PGRTR706 (Unsolicited: Initial Grade Change: SAP)
B/I- PGRTR702 (Finished Goods Adjustment) B- PGPCM042
(Inventory Transfer-SAP/-Rmail to SAP)
Rlink Server
F/A- PGLRM703 (Schedule Sequence/Order Date Change (TBD))
E = Solicited
I = Unsolicited
VB
LIMS
C
Existing Programs
D
A
Model
SQL
B/I
PI
These Are Model and LIMS Specific:
Process Control
C- PGRTR703 (Submitted by PRM at Campaign
Completion)
C- PGLIM703 (LIMS Campaign Close)
C- PGLIM702 (Sends PMU’s to LIMS)
Provox
D- PGTR705 (LIMS Grading)
PGPCM098 (Global Section Backup:Model
Specific)
34
SAP Master Recipe Design
MASTER BATCH MATERIAL
Each Order has One Operation
BULK MATERIAL
HAND ADD
AND
COLOR BLEND
MATERIAL
Mixer
Phase
Packaging
Extrusion
Phase
Phase
BOX
35
To Bulk
SAP Order Operations & Phases
36
SAP PP-PI Process Instructions/Messages
SAP R/3
PP-PI
Process
Instructions
Control Recipes
PSRLINK
PI
37
SAP PP-PI Process Instructions/Messages

AORD - Order Data


APHASE - Phase Data


including External Phases
AMAT - Material Allocation Info


including start/finish date/time, PolyOne ProdVers
Raw Material consumption
AMATP01 - Material Allocation Info

Finished Goods production
38
SAP PP-PI Process Instructions/Messages
SAP R/3
PP-PI
Process Messages
Process
Instructions
Control Recipes
PSRLINK
PI
39
SAP PP-PI Process Instructions/Messages

ACRST - Control Recipe status


ACONS - Goods Issue


Raw Material consumption (MAT_CONS)
APROD - Goods Receipt


Start/Processed/Discarded
Finished Goods production (MAT_PROD)
APHCON - Time Ticket Info

Confirmation Qty & Time
40
SAP Order Process Instructions
41
SAP Order Process Instr Characteristics
42
SAP Order Process Instructions in RLink
43
SAP Order Bill of Materials in RLink
44
RLink Translation Method
X Rcp1 Resin
Resin1 250#
X Rcp1 Resin
Resin1 250#
X Rcp1 ImpMod
ImpMod2 150#
X Rcp1 ImpMod
ImpMod2 150#
X Rcp1 Stab
Stab3 100#
X Rcp1 Stab
Stab3 100#
X Rcp1 Pigment
Pigment4 50#
Phase start
X Rcp1 Pigment
Pigment4 50#
Phase confirmation
X Rcp1 Resin
Resin1 230#
X Rcp1 ImpMod
ImpMod2 140#
X Rcp1 Stab
Stab3 110#
X Rcp1 Pigment
Pigment5 60#
Phase confirmation
Time
Tags
Recipe
Mat’l
Batch
Qty
Tags
Recipe
Mat’l
Batch
Qty
1st Conf.
Rcp1
Rcp1
Resin
ImpMod
Resin1
ImpMod2
250
150
2nd Conf.
Rcp1
Rcp1
Resin
ImpMod
Resin1
ImpMod2
480
290
Rcp1
Stab
Stab3
100
Rcp1
Pigment
Pigment4
50
Rcp1
Stab
Stab3
210
Rcp1
Pigment
Pigment4
50
45
Rcp1
Pigment
Pigment5
60
RLink Interface data in PI
46
RLink Interface data in PI
47
RLink Interface data in PI
48
SAP PP-PI Process Instructions/Messages
SAP R/3
PP-PI
Process Messages
PSRLINK
PI
49
SAP PP-PI Process Instructions/Messages

PI_CONS - Unsolicited CONS


PI_PROD - Unsolicited PROD


Move from QI, then Batch ID change
MATRANS2 - Rework CONS


unplanned production (SAP_TRAN)
MATRANS1 - FG Grading


unplanned consumption (SAP_TRAN)
Move from Blocked, then CONS
LINEVENT - Line Events

Populates custom SAP table
50
RLink Interface data in PI
51
RLink Alarming via PI tags
52
Manufacturing Systems Integration at
Manufacturing Integration History
Manual Plant pilot
•Scope & Design
•User Views
Automated Plant Project
•Scope & Design, Data Views
Lessons & Experiences
Questions?
53
Manufacturing Systems Integration at
Manufacturing Integration History
Manual Plant pilot
•Scope & Design
•User Views
Automated Plant Project
•Scope & Design, Data Views
Lessons & Experiences
Questions?
54