Paper company implements paperless manufacturing execution system

Vasu Alam

• New company formed January 2002 with the merger of Mead and Westvaco

• 2002 Sales $7.2 billion• 4 Business Units

– Packaging– Coated and Specialty Papers– Consumer and Office Products– Specialty Chemicals

PACKAGING• Bleached paperboard for use in

packaging or printing applications

• Used in beverage multi-packs and folding carton applications

• Coated papers for wraps and laminates

• Aseptic board for non-refrigerated food and beverage packaging

• Specialty paperboard for food applications

• Uncoated board for use in cups and plates

• Rigid plastic for use with high-end cosmetics and personal care items

• Proprietary injection-molded product for CDs, DVDs and software packaging

• Papers for catalogs, annual reports, magazines and coffee table books

• Digital papers for commercial and desktop printing

• Carbonless and security papers for business forms and receipts

• Label papers for food and beverages

• Wraps for laminating folding cartons

Differentiated papers improve customers’ products

COATED & SPECIALTY PAPERS

• First name in school, office and time management products

One of the largest producers of envelopes worldwide personal use direct mail

financial billing

CONSUMER & OFFICE PRODUCTS

• World’s leading supplier of activated carbons for automotive emissions controls

• World's largest supplier of asphalt emulsifiers for innovative, specialty applications

• Leading U.S. supplier printing ink resins

SPECIALTYCHEMICALS

Product Diversity• Coated & Specialty Papers

•Rolls of coated paper•Rolls, skidded sheets and cartons of coated paper•Rolls and cartons or carbonless paper•Rolls of carbonless paper•Rolls of decorative and overlay papers for laminates, tape, friction and filter papers

• Consumer & Office Products•Cases, Eaches, pallets and interpacks

• Specialty Chemical•Pallets, Totes, Drums and Bulk Bags

• Packaging•Rolls and Skidded Sheets of Unbleached Coated Board

RF Rollout TimelineMahrt Mill --> May 2000

Rumford & Escanaba Mills --> Mar 2001Chillicothe Mill --> Jun 2001Fremont Mill --> Dec 2001

South Lee, Laurel & Potsdam Specialty Mills --> April 2002Devon, England Specialty Mill --> June 2002Blair, St Joe, Garland, & Garden Grove Plants --> Nov 2002Hilroy, Canada Plant --> Nov 2002Nuevo Laredo, Mexico Plant --> Nov 2002Charleston, Covington & Wickliffe Plants --> Dec 2002

Wickliffe Mill --> Jun 2003Luke Mill --> Nov 2003

Packaging Resource Mills --> 2005

Integration “Middleware” Partner

RF Equipment RF Equipment PartnerPartner• MobileLAN™ 2100 Access Point

• 2425 Keypad Handheld Unit

• 6400 Keypad Handheld Unit

• 5055 Vehicle Mount Unit

• DataPass 3.0

What value does Datapass add?

• Combines many SAP transactions into simpler barcode enabled transactions

• Allows shipping to continue in the event SAP becomes unavailable or experiences a network outage

• Provides real time mission critical data to SAP

What does Datapass do for MWV?

• Allows end users to manage product on the plant floor and warehouse

• Displays R/3 information real time to the mobile worker

• Handles and simplifies document printing

• Provides Yard Management (trailers/railcars)

DataPass Architecture

SAP R/3Datapass SQL

Server

DB2Replicated Shipping Data

Handheld VMU Telnet

Shipping & delivery information transferred by IDoc or RFC

DataPass Transactions

Number of Transactions:

• Coated and Specialty Papers: 46– 7 X 24 mode: 23

• Consumer and Office Products: 39

• Specialty Chemical: 24

Yard Management

Yard management is the process and procedure of managing a pool of trailers, railcars, and containers used for outbound transportation at a mill or plant site.

When the vehicle arrives at the plant, a transaction is completed to add the vehicle into a plant, storage location and warehouse. Vehicles are referred to in SAP R/3 as storage units. Once the vehicle is added to the system it is directed to a storage bin which may be a dock door or a yard.

Yard Storage Bins

CDK(Railcar Spots)

FLR(Shipping

Floor)

Shipping Floor Trailer Yard

GuardHouse

TKE(empty lot)

TKF(full lot)

TBO(badorderlot)

TDK(Truck Docks)

IWS(storage)

ITD(TruckDocks)

ICD(Car

Docks)

CRF(full lot)

Rail Yard CRE(empty lot)

CRP(recycle plants)

Storage Unit Managed

Storage Bins

Yard Management

Vehicle MovementsThe yard dispatcher uses several transactions to manage and monitor the yard. Moving vehicles from one location to another within the yard is handled in two different ways:

• Vehicle movements may be recorded as the vehicles are moved, using DataPass or SAP R/3. A one-step transfer order is created and confirmed.• Vehicle movements may also be planned in advance by the yard dispatcher who creates two step transfer orders (TO’s). These two step TO’s communicate which vehicles should be moved and to what location. The yard jockey reads a report to view the requests (via DataPass), performs the physical vehicle movement, and then confirms the vehicle movement using DataPass.

Yard Movements

CDK(Railcar Spots)

FLR(Shipping

Floor)

Shipping FloorOne Step

Two Step Trailer Yard

GuardHouse

TKE(empty lot)

TKF(full lot)

TBO(badorderlot)

TDK(Truck Docks)

ReceiveRailcars

ShipRailcars

IWS(storage)

ITD(TruckDocks)

ICD(Car

Docks)

CRF(full lot)

Rail Yard CRE(empty lot)

CRP(recycle plants)

Warehouse

Questions

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Session Code: 4501