Kris.zywicki@dowcorning.com
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Today’ Presentation
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Who we are
SAP Architecture
MES Architecture
SAP R/3 PPPI Rlink Implementations
Integration Specification
What’s next
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Dow Corning Corporation
• World leader in silicon technology
• Formed in 1943 in Midland, Michigan
• Company shares are equally owned by The Dow
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Chemical Company and Corning Incorporated
Over 5,000 products
Over 45,000 customers worldwide
60% of business outside the U.S.
Sales of $2.6 billion
Over 9,000 employees worldwide
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Dow Corning Industries
• Electrical/Electronics
• Food Processing
• Industrial Maintenance
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Aerospace
Automotive
Chemicals/ Petrochemicals
Construction
Consumer Products
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& Production
Medical Products
Paint & Coatings
Personal, Household
& Automotive Care
Pharmaceuticals
Plastics
Pressure-Sensitive
Adhesives
Textiles & Leather
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SAP R/3 ARCHITECTURE
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SAP R/3 ARCHITECTURE
100+ users
Brazil LSA
SAP R/3
Release 3.0f
Brazil
100+ users
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DCC ABAP Programs
DCC ABAP Applications]
DCC ABAP Reports
User Exits
Batch Jobs
Variants
EHS
SAP R/3
Release 3.0f/2.2b
Material Safety
35 users
300 planned
APO
SAP R/3
Release 4.6a/2.0a
Advanced Planning
&
Scheduling
• Documentum – Document imaging
• Global ADC(Barcoding)
• Global EDI – Harbinger
• ADP – U.S. Payroll
CORE
SAP R/3
Release 4.6b
• Extranet Order Status – Haht
8500+ users
9 Languages
90+ locations
• Jetform – Document printing
Bolt-ons/Interfaces
SD, MM, PP, FI, CO,
QM, IM, WM,PM,AA,
AP, AR, Product Cost
ALE
RFC
ATP
BAPI
4000+ users
8000+ Planned
80+ users
2200+ Planned
BW
SAP R/3
Release 4.6c/2.0b
Advanced Planning
&
Scheduling
• Global Data Warehouse(GDW)
CRM
SAP R/3
Release 4.6a/2.0b
Customer RelationShip Mgmt
ESS/ITS
SAP R/3
Release 2.0
Employee Self
Service
• 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
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SAP R/3 IMPLEMENATION STATUS
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9000 users
1400 to 1500 concurrent users
1100 double byte users
24 X 7 operations (3 hours - Sunday Morning maintenance)
52 DC Legal Entities on SAP
110 SAP Plants(sites) on SAP
28 Manufacturing Plants
28 Warehousing & Distribution Sites
50,000+ Materials(Raw Materials-ROH & IntermediatesHALB)
80,000+ MRO Materials(ERSA,NLAG)
60,000+ Customers
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SAP MODULES
FI
AP, AR, GL, SL, AA
CO
Cost Ctr, Ord & Proj, Prod Cost, PA, PCA
AM
Inv Ctrl, Asset Acctng
MM
PUR, IS, WM, IM, IV
SD
Sales, Shipping, Transp, Billing, Pricing,Credit
PM
Maint Ord, Equip BOM, Preventive Maint
PP
SOP, MRP, MPS, SFC, IS, PC, CRP, SYS, PP/PI
QM
Certs, Insp Planning, Q-notifications, RR
HR
ORG, PAD, TIM, TRV, PAY, INT
EHS
Material Safety Data Sheets
BW
Product cost reporting, Global Sales Finance reporting, DSI
APO
Demand Planning, Supply Network Planning
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Countries
Implementations covering 19 localized countries:
AMERICAS
US
Mexico
Canada
Brazil
ASIA
Australia
Hong Kong
New Zealand
Malaysia
Taiwan
Japan
China
Thailand
Korea
Singapore
EUROPE
Belgium
UK
Italy
France
Spain
Germany
(Others: Poland, Sweden,
Austria)
(Others: Indonesia,
Philippines, India)
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Manufacturing Systems
• Team Mission: Provide and support total
solutions that optimize the product delivery
business processes.
• Team’s Product and Services: Application
Systems and I/T expertise
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MES - Inventory and Delivery
• ADC (Bar-coding) - Functionality
– Inventory Accuracy Improvement
– Automated Transactions for IM and WM
modules
– Operator entry of data for IM and WM
transactions
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MES - Inventory and Delivery
• 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
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MES - Quality Management
• Quality Management
• Laboratory Information Management (LIMS) - Manage
Sample tracking and test results for Quality Assurance
and Analytical laboratories
• Provide automated interfaces to SAP for the QM
Module
• Provide automated interfaces to laboratory instruments
(Gas Chromatography, Viscometers, etc.)
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MES - Production Execution
• 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
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MES - Summary
• Global systems –
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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.
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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.
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Business Drivers
• Efficient Manufacturing Transactions
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– through automated routine tasks and coordinated activities
through better communications.
Integrated Processes
– vertically linking production within the manufacturing
processes.
Integrated Information Systems
– allowing for improved management decision making
through measured and monitored quality and cost control.
Reduced Product Variability
– in manufacturing, produce a specific material one way and
only one way.
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What to Integrate
PRODUCT
DEFINITION
FINANCIALS
ORDER
MANAGEMENT
ENTERPRISE
SAP R/3
COSTING
FORECASTING
PURCHASING
INVENTORY
MANAGEMENT
QUALITY
MANAGEMENT
MATERIAL
USAGE
HUMAN
RESOURCES
ORDER STATUS,COMPLETIONS,
START/STOP TIMES, RESOURCE,
LABOR, MATERIAL STATUS,
ACTUAL BILL OF MATERIAL,
PRODUCTION QUALITY DATA,
SCRAP, WASTE
PRODUCT DEMAND, BILL OF MATERIAL
RECIPE, FORMULATION, RESOURCES,
LABOR, INVENTORY STATUS, WORK
INSTRUCTIONS
DOCUMENT
CONTROL
SCHEDULING
PRODUCTION
HISTORY
RESOURCES
FACTORY FLOOR
MES
PRODUCT
TRACKING
MAINTENANCE
MANAGEMENT
PROCESS
ANALYSIS
PRODUCTION
DISPATCHING
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Integration Architecture
SAP R/3 SYSTEM
PM
PP-PI
QM
NETWORK
Rlink
PROCESS INFORMATION SYSTEM
PI - BATCH
CALCULATION
ENGINE
REAL TIME
DATABASE
HISTORIAN
S PC
NETWORK
LIMS
SCADA
DCS
MANUAL
INPUT
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Production Information Flow
• Schedule Information
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• Goods Receipt
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Material Number
Actual Quantity
Operation/Phase
etc.
Process Order/Batch Number
Resource
Proposed Quantity
etc.
Rlink Layer
• Goods Issue
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Material Number
Actual Quantity
Operation/Phase
etc.
• Process Control
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Key Process Information
Operation/Phase
Test Reduction /
Parametric Acceptance
Process Variability
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Integration Goals
• Automate production recording
• Improve Data Accuracy
• Improve timeliness of data reporting
• Eliminate Production Recorders
• Reconcile physical and SAP inventory automatically
• Reduce Cost Variances
• E-Commerce support
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Integration Scenarios
• DCS = Source of Data.
1.Continuous Processes.
2.Trailer Moves.
3.Mass Balance.
4.Batch Processes
5.Material movements
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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) ...“
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OSI Rlink Targets
– Continuous processes
• for PO duration set start date and time
• for reporting interval set as shift, day, hour, etc.
– Batch processes w/out Batch Engine
• PI-ProcessBook/VB applications as campaign
manager
– Batch processes with Batch Engine
• Foxboro IA Batch, Intellution iBatch
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Midland TCS
Blend
Station
Virtual
Inventory
26 Batch
CVD Reactors
Polysilicon
HOST
Reactor
HCL to Midland
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Procedure to Reconcile Physical Inventory
and SAP Inventory Automatically.
In PI
Flow In
=
Change in Tank Level
+
Flow Out.
Where Flow Out and Level are Measured
In SAP
Change in Tank Level
=
Flow In
-
Flow Out.
Where Flow In and Out are reported through PSR LINK from PI
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Integration Specification
• Makes Manufacturing document...
– what their process is
– what parameters need to be captured for the
Business System and Business Recipe
development
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Integration Specification for each process
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Integration Skills for Integration
In te g r a tio n S k ills
R e q u ir e d to
In te g r a te th e P la n t
F lo o r to th e
E n te r p r is e
E n t e r p r is e D o m a in
B u s in e s s P r o c e s s
C o n tr o l S y s te m :
* S A P (E R P )
B u s in e s s P r o c e s s
S k ills
P r o c e s s In te g r a tio n
S k ills
E x e c u t io n D o m a in
In t e g r a t io n A p p s :
* F o x b o r o B IS
* O S I P S - R L in k
S ta n d a r d :
* IS A S P 9 5
P r o c e s s In fo r m a tio n
S k ills
P ro cess
In f o r m a t io n
S y s te m :
* O S I P I ( P IW )
B a tc h E n g in e
S k ills
P ro c e s s C o n tro l
S k ills
P r o c e s s C o n tr o l
D o m a in
M a n u f a c t u r in g
P r o c e s s C o n tr o l
S y s te m :
* F o x b o r o (D C S )
* In t e ll u t io n
(S C A D A )
B a t c h E n g in e :
*F o xb o ro IA B a t c h
* In t e ll u t io n iB a t c h
S ta n d a r d :
* IS A S 8 8
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•What’s next?
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OSI Rlink
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Robust
Reliable
Powerful
Flexible
Perfect fit
Always works!!!
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