Manufacturing

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Manufacturing Systems Integration at
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MA Hanna Yesterday

• Headquartered in Cleveland, Ohio
• Employs 7,000 people worldwide
• 2.3 Billion in Sales - 1999
• Resin Distribution
• 460 million
• Rubber Compounding
• 529 million
• Color Compounding
• 483 million
• Plastics Compounding
• 437 million
• Shapes
• 391 million

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Geon Yesterday

• Headquartered in Avon Lake, Ohio
• Employs 3,100 people worldwide
• Worlds largest producer of vinyl (PVC) compounds
  
• 820 Million
• North Americas largest producer of dispersion
  resins formulators
• 235 million
• Engineered Films
• 215 million
• Joint Venture with OxyChem (OxyVinyls) various
  joint ventures worldwide

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Strategy
D e s i g n e r / A s s e m b l e r
P o l y m e r s
Building Materials
Automotive
C o n s u m e r s
Appliances Business Equipment
A d d i t i v e s
Packaging
Packaging
Consumer Products
Consumer Products
Communications/ Electronics
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Manufacturing Systems Integration at

• Manufacturing Integration History
• Manual Plant pilot
• Scope Design
• User Views
• Automated Plant Project
• Scope Design, Data Views
• Lessons Experiences
• Questions?

6

In 1988, we began our Computer Integrated
Enterprise vision by attempting to simplify,
automate and integrate our internal processes

• This initiative was focused in large part on our
  compound manufacturing assets and product line.

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Geons Computing Environment
NT
Financial System
Order Entry System
Procurement
SID
Corporate
Forecasting/ Planning System
Planning
Distribution
Manufacturing Execution System (MES) - PROCESS/1
Plant
LIMS
CHAMPS
Inventory Management
Process Model (SCADA)
Line
Run Tracking
Process Control
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High Level Information Flow
PREPARE FOR PRODUCTION RUNS
EXECUTE PRODUCTION RUNS
ANALYZE PRODUCTION RESULTS
KEY FUNCTIONS
OUTPUTS/ INPUTS
KEY FUNCTIONS
OUTPUTS/ INPUTS
KEY FUNCTIONS
INPUTS
OUTPUTS

• RUN HISTORY
• PRODUCTION RUN AUDIT TRAIL
• MATERIAL USAGE
• FINISHED GOODS PRODUCTION
• RUN START/STOP TIMES
• DOWNTIME EVENTS
• SALVAGE
• PROCESS VARIABLES

PREPARE LINE RECIPE PACKET
PICK RAW MATERIALS FOR 3RD 4TH FLOOR
MATERIAL PERFORMANCE VIEW/UPDATE
MATERIAL DELIVERIES
LOT SPECIFIC RECIPE PACKET
RUN PERFORMANCE MEASURES
ANALYZE RUN PERFORMANCE
ORDER, RECEIVE, AND BAR-CODE MATERIALS
MAKE-UP BULK, MASTER BATCH AND HAND-ADD MATERIALS
PERFORM SQC ANALYSIS
SET UP SPC SPECS
EXECUTE, CONTROL, AND MONITOR RUN
BAR-CODED RAW MATERIALS
SPC/SQC ANALYSIS RESULTS
SPC/SQC ANALYSIS RESULTS
TRACK ACTUAL RUN PERFORMANCE
RECIPE ADJUSTMENTS
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The Manufacturing Systems Journey
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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
• Data Acquisition
• standard data acquisition approach
• standard data elements
• standard data structure
• Manual data capture where controller data feeds
  unavailable
• Line Recipe Management
• LRM capability extended to plants where it does
  not exist
• PRM can be supported with more common skills

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Mfg. study revealed several things
Mfg. Systems Strategy Study

• 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

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Manufacturing Systems Integration at

• Manufacturing Integration History
• Manual Plant pilot
• Scope Design
• User Views
• Automated Plant Project
• Scope Design
• User Views
• Lessons Experiences
• Questions?

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OSI RLink Pilot
At Farmingdale Plant Prove OSI PI link to SAP

• Manual Data entry to OSI PI

• Automatic interface to SAP via OSI RLink

• Ability to analyze data in OSI PI

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SAP Master Recipe Design
Two distinct Orders
MASTER BATCH MATERIAL
BULK MATERIAL
HAND ADD AND COLOR BLEND MATERIAL
Order 1
Order 2

• Each Order
• one operation
• one phase

BOX
To Bulk
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SAP PP-PI Process Instructions/Messages
Standard PSRLink Interface for Informational Data
AMAT AMATP01 APHASE AORD APHAR
SAP R/3
PP-PI

PSRLINK
PI
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SAP PP-PI Process Instructions/Messages

• AORD - Order Data
• including start/finish date/time
• APHASE - Phase Data
• including External Phases
• AMAT - Material Allocation Info
• Raw Material consumption
• AMATP01 - Material Allocation Info
• Finished Goods production
• APHAR - Phase Parameter
• Blender Batchsize

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SAP PP-PI Process Instructions/Messages
Standard PSRLink Interface for Process Data
Request ACONS APROD APHCON ACRST
SAP R/3
PP-PI

PSRLINK
PI
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SAP PP-PI Process Instructions/Messages

• ACRST - Control Recipe status
• Start/Processed/Discarded
• ACONS - Goods Issue
• Raw Material consumption (MAT_CONS)
• APROD - Goods Receipt
• Finished Goods production (MAT_PROD)
• APHCON - Time Ticket Info
• Confirmation Qty Time

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SAP Order Process Instructions
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SAP Order Process Instructions in RLink
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RLink Translation Method

• Material Tags (Batch Qty)
• Resin
• Impact Modifier
• Stabilizer
• Pigment

1st Conf. Resin1, 250 ImpMod2, 150 Stab3,
100 Pigment4, 50
2nd Conf. Resin1, 480 ImpMod2, 290 Stab3,
210 Pigment4, 50 Pigment5, 60
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Manufacturing Systems Integration at

• Manufacturing Integration History
• Manual Plant pilot
• Scope Design
• User Views
• Automated Plant Project
• Scope Design, Data Views
• Lessons Experiences
• Questions?

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Starting Recipe Phase
Process Orders are sorted by Start Date and mimic
the ZSCH screen in SAP which is still used to
schedule production
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Blender Production Reporting
Enter the correct Batch numbers for all the RM
you used with a drop down!
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Blender Batch Process Data
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Compound Production Reporting
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Compound Cont. Process Data
You can quickly see process data trends right on
the screen
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User Developed Custom Apps
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User Developed Custom Apps
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User Developed Custom Apps
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Manufacturing Systems Integration at

• Manufacturing Integration History
• Manual Plant pilot
• Scope Design
• User Views
• Automated Plant Project
• Scope Design, Data Views
• Lessons Experiences
• Questions?

32
The Next Step
At a Legacy Plant Prove No Process/1

• Proven Auto interface to SAP via OSI RLink

• Automatic PCS interface to OSI PI/RLink

• Interface OSI PI/RLINK with Vax LRM/PRM

on Vax

• Ability to analyze data in OSI PI

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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) B- PGRTR710 /
702 (Production/Finished Goods Adjustment) B-
PGRTR706 (Grade Change P1 SAP) B- PGRTR711
(Campaign Pending Close) B- PGRTR704 (Campaign
Close) B- PGRTR720 (Downtime-Function in SAP) B-
PGPCM042 (Inventory Transfer)(.exe) B- PGPCM040
(Inventory Transferpart of 042) B- PGRTR702
(Production Part of PGRTR710) B- PGRTR800
(Vendor Lot Modification Consumption) B-
PGRTR716 (MB/CB Reconciliation)
PGRTR706 (R-Mail Grade Change)
A
B
C
D
C- PGRTR703 (Submitted by PRM at Campaign
Completion) C- PGLIM703 (LIMS Campaign Close) C-
PGLIM702 (Sends PMUs to LIMS) D- PGTR705 (LIMS
Grading)
Process Control
Question PGPCM098 (Global Section Backup-BMAT)
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New Process Model/RLink/SAP Interfaces
F/A-(Order DownLoad) F/A- PGLRM701 (BOM
Information) F/A- PGLRM702 (Campaign
Information) B/E- PGRTR701 (Consumption) B/E-
PGRTR704 (Campaign Finish) B/E- PGRTR710
(Production) B/I- PGRTR716-(Consumption 4hr.
delay) B/I -PGRTR720 (Line events) B/I- PGRTR706
(Unsolicited Initial Grade Change SAP) B/I-
PGRTR702 (Finished Goods Adjustment) B- PGPCM042
(Inventory Transfer-SAP/-Rmail to SAP) F/A-
PGLRM703 (Schedule Sequence/Order Date Change
(TBD)) E Solicited I Unsolicited
E/I
F
SQL
VB
A
B/I
C
Existing Programs
D
These Are Model and LIMS Specific C- PGRTR703
(Submitted by PRM at Campaign Completion) C-
PGLIM703 (LIMS Campaign Close) C- PGLIM702
(Sends PMUs to LIMS) D- PGTR705 (LIMS
Grading) PGPCM098 (Global Section BackupModel
Specific)
Process Control
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SAP Master Recipe Design
Each Order has One Operation
MASTER BATCH MATERIAL
BULK MATERIAL
HAND ADD AND COLOR BLEND MATERIAL
Mixer Phase
Packaging Phase
Extrusion Phase
BOX
To Bulk
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SAP Order Operations Phases
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SAP PP-PI Process Instructions/Messages
Standard PSRLink Interface for Informational Data
AMAT AMATP01 APHASE AORD
SAP R/3
PP-PI

PSRLINK
PI
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SAP PP-PI Process Instructions/Messages

• AORD - Order Data
• including start/finish date/time, PolyOne
  ProdVers
• APHASE - Phase Data
• including External Phases
• AMAT - Material Allocation Info
• Raw Material consumption
• AMATP01 - Material Allocation Info
• Finished Goods production

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SAP PP-PI Process Instructions/Messages
Standard PSRLink Interface for Process Data
Request ACONS APROD APHCON ACRST
SAP R/3
PP-PI

PSRLINK
PI
40
SAP PP-PI Process Instructions/Messages

• ACRST - Control Recipe status
• Start/Processed/Discarded
• ACONS - Goods Issue
• Raw Material consumption (MAT_CONS)
• APROD - Goods Receipt
• Finished Goods production (MAT_PROD)
• APHCON - Time Ticket Info
• Confirmation Qty Time

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SAP Order Process Instructions
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SAP Order Process Instr Characteristics
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SAP Order Process Instructions in RLink
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SAP Order Bill of Materials in RLink
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RLink Translation Method
Tags Recipe Matl Batch Qty
1st Conf. Rcp1 Rcp1 Rcp1 Rcp1 Resin ImpMod Stab
Pigment Resin1 ImpMod2 Stab3 Pigment4 250
150 100 50
2nd Conf. Rcp1 Rcp1 Rcp1 Rcp1 Rcp1 Resin ImpMod
Stab Pigment Pigment Resin1 ImpMod2 Stab3 Pigm
ent4 Pigment5 480 290 210 50 60
Tags Recipe Matl Batch Qty
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RLink Interface data in PI
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RLink Interface data in PI
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RLink Interface data in PI
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SAP PP-PI Process Instructions/Messages
Standard PSRLink Interface for Unsolicited
Process Data ACONS APROD MATRANS1 MATRANS2 LINEVEN
T
SAP R/3
PP-PI
PSRLINK
PI
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SAP PP-PI Process Instructions/Messages

• PI_CONS - Unsolicited CONS
• unplanned consumption (SAP_TRAN)
• PI_PROD - Unsolicited PROD
• unplanned production (SAP_TRAN)
• MATRANS1 - FG Grading
• Move from QI, then Batch ID change
• MATRANS2 - Rework CONS
• Move from Blocked, then CONS
• LINEVENT - Line Events
• Populates custom SAP table

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RLink Interface data in PI
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RLink Alarming via PI tags
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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
Manufacturing Systems Integration at

• Manufacturing Integration History
• Manual Plant pilot
• Scope Design
• User Views
• Automated Plant Project
• Scope Design, Data Views
• Lessons Experiences
• Questions?