Kris.zywickidowcorning.com

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Kris.zywicki_at_dowcorning.com
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Today Presentation

• Who we are
• SAP Architecture
• MES Architecture
• SAP R/3 PPPI Rlink Implementations
• Integration Specification
• Whats 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
  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 Production
• Medical Products
• Paint Coatings
• Personal, Household
  Automotive Care
• Pharmaceuticals
• Plastics
• Pressure-Sensitive Adhesives
• Textiles Leather

• Aerospace
• Automotive
• Chemicals/ Petrochemicals
• Construction
• Consumer Products

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SAP R/3 ARCHITECTURE
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SAP R/3 ARCHITECTURE
Brazil LSA SAP R/3 Release 3.0f Brazil

• DCC ABAP Programs
• DCC ABAP Applications
• DCC ABAP Reports
• User Exits
• Batch Jobs
• Variants

100 users

• 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

EHS SAP R/3 Release 3.0f/2.2b Material Safety
100 users
CORE SAP R/3 Release 4.6b SD, MM, PP, FI, CO, QM,
IM, WM,PM,AA, AP, AR, Product Cost
8500 users 9 Languages 90 locations
APO SAP R/3 Release 4.6a/2.0a Advanced Planning
Scheduling
35 users 300 planned
Bolt-ons/Interfaces ALE RFC ATP BAPI
4000 users 8000 Planned
ESS/ITS SAP R/3 Release 2.0 Employee Self Service
BW SAP R/3 Release 4.6c/2.0b Advanced Planning
Scheduling
80 users 2200 Planned
CRM SAP R/3 Release 4.6a/2.0b Customer
Relation- Ship Mgmt
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SAP R/3 IMPLEMENATION STATUS

• 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
  Intermediates-HALB)
• 80,000 MRO Materials(ERSA,NLAG)
• 60,000 Customers

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

• Implementations covering 19 localized
  countries
• AMERICAS ASIA EUROPE
• US Australia Belgium
• Mexico Hong Kong UK
• Canada New Zealand Italy
• Brazil Malaysia France
• Taiwan Spain
• Japan Germany
• China (Others Poland, Sweden,
• Thailand Austria)
• Korea
• Singapore (Others Indonesia,
• Philippines, India)

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Manufacturing Systems

• Team Mission Provide and support total
  solutions that optimize the product delivery
  business processes.
• Teams 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
• 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
• 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
ORDER MANAGEMENT
FINANCIALS
SCHEDULING
ENTERPRISE SAP R/3
COSTING
HUMAN RESOURCES
FORECASTING
INVENTORY MANAGEMENT
PURCHASING
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
PRODUCTION HISTORY
DOCUMENT CONTROL
RESOURCES
MAINTENANCE MANAGEMENT
QUALITY MANAGEMENT
FACTORY FLOOR MES
PROCESS ANALYSIS
MATERIAL USAGE
PRODUCTION DISPATCHING
PRODUCT TRACKING
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Integration Architecture
SAP R/3 SYSTEM
NETWORK
Rlink
NETWORK
DCS
SCADA
LIMS
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Production Information Flow
Rlink Layer

• 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

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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.
• Continuous Processes.
• Trailer Moves.
• Mass Balance.
• Batch Processes
• 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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Procedure to Reconcile Physical Inventory and SAP
Inventory Automatically.
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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
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• Whats next?

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OSI Rlink

• Robust
• Reliable
• Powerful
• Flexible
• Perfect fit
• Always works!!!