SIEMENS POWER GENERATION

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SIEMENS POWER GENERATION Phil Scotson
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Presentation structure

• Company background
• ERP system background
• Scope of use defining the interfaces
• Interfaces in detail
• Conclusion

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The Organizational Structure of SiemensBusiness
Segments and Groups
Managing Board
Siemens at a Glance Siemens PG Profile Siemens
PG Key Figures
Power
Medical
Information andCommunication
Power Generation (PG)
Information andCommunication Networks (ICN)
Medical Solutions (Med)
Power Transmission and Distribution (PTD)
Information andCommunication Mobile (ICM)
Lighting
Automation and Control
Siemens Business ServicesGmbH Co. OHG (SBS)
Osram GmbH
Automation and Drives (AD)
Transportation
Finance and Real Estate
Industrial Solutions- and Services (IS)
Siemens Financial Services GmbH (SFS)
Transportation Systems (TS)
Siemens Dematic AG (SD)
Siemens VDO Automotive AG (SV)
Siemens BuildingTechnologies AG (SBT)
Siemens Real Estate (SRE)
Stand 01.01.2001
Regional organization Regional Offices Regional
Companies, Representative Offices, agencies
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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 (OM)
  agreements
• Leading vendor of industrial applications
• Successful integration of the fossil division of
  Westinghouse
• Innovation and technical advancement

Power Generation
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C.A. Parsons Works
Balancing Facilities
Generator Repair
Blade Manufacture
Main Office Block
Machining Facilities
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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
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(No Transcript)
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Large complex parts eg Casings and Rotors
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Production Facilities
Heavy Machining
Turbine Assembly
Generator Rotors
Blade Manufacture
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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 Ef
ficiency Improvements Life Extension and
Integrity Maintainability Improvements Latest
Technology
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Customers Power Station owners
SPG History SPG at a Glance SPG
Capabilities SPG Customers References
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ERP System background
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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 !

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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

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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 1 000 MBytes

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Sample Avante GUI screen
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The extent of Avanté
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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

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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

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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

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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

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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

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Other interfaces

• Site Operations
• To Site Ops - Work order routings for
  validation _at_ 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

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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

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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 Operations _at_ Power Stations

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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

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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

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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 !?!??

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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

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The End
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