WE HELP YOU INVENT THE FUTURE.TM
WE HELP YOU INVENT THE FUTURE.TM
Today’ PresentationToday’ Presentation
• Who we areWho we are
• SAP ArchitectureSAP Architecture
• MES ArchitectureMES Architecture
• SAP R/3 PPPI Rlink ImplementationsSAP R/3 PPPI Rlink Implementations
• Integration SpecificationIntegration Specification
• What’s nextWhat’s next
WE HELP YOU INVENT THE FUTURE.TM
Dow Corning CorporationDow Corning Corporation
• World leader in silicon technologyWorld leader in silicon technology
• Formed in 1943 in Midland, MichiganFormed in 1943 in Midland, Michigan
• Company shares are equally owned by The Dow Chemical Company shares are equally owned by The Dow Chemical Company and Corning IncorporatedCompany and Corning Incorporated
• Over 5,000 products Over 5,000 products
• Over 45,000 customers worldwide Over 45,000 customers worldwide
• 60% of business outside the U.S. 60% of business outside the U.S.
• Sales of $2.6 billion Sales of $2.6 billion
• Over 9,000 employees worldwide Over 9,000 employees worldwide
WE HELP YOU INVENT THE FUTURE.TM
Dow Corning IndustriesDow Corning Industries
• AerospaceAerospace
• AutomotiveAutomotive
• Chemicals/ PetrochemicalsChemicals/ Petrochemicals
• ConstructionConstruction
• Consumer ProductsConsumer Products
• Electrical/ElectronicsElectrical/Electronics• Food ProcessingFood Processing• Industrial Industrial
Maintenance & Maintenance & ProductionProduction
• Medical ProductsMedical Products• Paint & CoatingsPaint & Coatings• Personal, Household Personal, Household
& & Automotive CareAutomotive Care
• PharmaceuticalsPharmaceuticals• PlasticsPlastics• Pressure-Sensitive Pressure-Sensitive
AdhesivesAdhesives• Textiles & LeatherTextiles & Leather
WE HELP YOU INVENT THE FUTURE.TM
SAP R/3 ARCHITECTURESAP R/3 ARCHITECTURE
WE HELP YOU INVENT THE FUTURE.TM
SAP R/3 ARCHITECTURESAP R/3 ARCHITECTURE
CORESAP R/3
Release 4.6bSD, MM, PP, FI, CO,QM, IM, WM,PM,AA,AP, AR, Product Cost
CORESAP R/3
Release 4.6bSD, MM, PP, FI, CO,QM, IM, WM,PM,AA,AP, AR, Product Cost
EHSSAP R/3
Release 3.0f/2.2bMaterial Safety
EHSSAP R/3
Release 3.0f/2.2bMaterial Safety
APOSAP R/3
Release 4.6a/2.0aAdvanced Planning
& Scheduling
APOSAP R/3
Release 4.6a/2.0aAdvanced Planning
& Scheduling
BWSAP R/3
Release 4.6c/2.0bAdvanced Planning
& Scheduling
BWSAP R/3
Release 4.6c/2.0bAdvanced Planning
& Scheduling
CRMSAP R/3
Release 4.6a/2.0bCustomer Relation-
Ship Mgmt
CRMSAP R/3
Release 4.6a/2.0bCustomer Relation-
Ship Mgmt
ESS/ITSSAP R/3
Release 2.0Employee Self
Service
ESS/ITSSAP R/3
Release 2.0Employee Self
Service
• 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
• 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
Brazil LSASAP R/3
Release 3.0fBrazil
Brazil LSASAP R/3
Release 3.0fBrazil
• DCC ABAP Programs• DCC ABAP Applications]• DCC ABAP Reports• User Exits• Batch Jobs• Variants
• DCC ABAP Programs• DCC ABAP Applications]• DCC ABAP Reports• User Exits• Batch Jobs• Variants
8500+ users9 Languages90+ locations
8500+ users9 Languages90+ locations
100+ users100+ users
100+ users100+ users
35 users300 planned
35 users300 planned
80+ users2200+
Planned
80+ users2200+
Planned
4000+ users8000+ Planned4000+ users
8000+ Planned
Bolt-ons/Interfaces
ALERFCATPBAPI
WE HELP YOU INVENT THE FUTURE.TM
SAP R/3 IMPLEMENATION STATUSSAP R/3 IMPLEMENATION STATUS• 9000 users9000 users• 1400 to 1500 concurrent users1400 to 1500 concurrent users• 1100 double byte users1100 double byte users
• 24 X 7 operations (3 hours - Sunday Morning maintenance)24 X 7 operations (3 hours - Sunday Morning maintenance)• 52 DC Legal Entities on SAP52 DC Legal Entities on SAP• 110 SAP Plants(sites) on SAP 110 SAP Plants(sites) on SAP • 28 Manufacturing Plants 28 Manufacturing Plants • 28 Warehousing & Distribution Sites28 Warehousing & Distribution Sites• 50,000+ Materials(Raw Materials-ROH & Intermediates-HALB)50,000+ Materials(Raw Materials-ROH & Intermediates-HALB)• 80,000+ MRO Materials(ERSA,NLAG)80,000+ MRO Materials(ERSA,NLAG)• 60,000+ Customers60,000+ Customers
WE HELP YOU INVENT THE FUTURE.TM
SAP MODULESSAP MODULES
Demand Planning, Supply Network PlanningDemand Planning, Supply Network PlanningAPOAPO
Product cost reporting, Global Sales Finance reporting, DSIProduct cost reporting, Global Sales Finance reporting, DSIBWBW
Material Safety Data SheetsMaterial Safety Data SheetsEHSEHS
ORG, PAD, TIM, TRV, PAY, INTORG, PAD, TIM, TRV, PAY, INTHRHR
Certs, Insp Planning, Q-notifications, RRCerts, Insp Planning, Q-notifications, RRQMQM
SOP, MRP, MPS, SFC, IS, PC, CRP, SYS, PP/PISOP, MRP, MPS, SFC, IS, PC, CRP, SYS, PP/PIPPPP
Maint Ord, Equip BOM, Preventive MaintMaint Ord, Equip BOM, Preventive MaintPMPM
Sales, Shipping, Transp, Billing, Pricing,CreditSales, Shipping, Transp, Billing, Pricing,CreditSDSD
PUR, IS, WM, IM, IVPUR, IS, WM, IM, IVMMMM
Inv Ctrl, Asset AcctngInv Ctrl, Asset AcctngAMAM
Cost Ctr, Ord & Proj, Prod Cost, PA, PCACost Ctr, Ord & Proj, Prod Cost, PA, PCACOCO
AP, AR, GL, SL, AAAP, AR, GL, SL, AAFIFI
WE HELP YOU INVENT THE FUTURE.TM
CountriesCountries
Implementations covering 19 localized countries:Implementations covering 19 localized countries:
AMERICASAMERICAS ASIAASIA EUROPEEUROPEUSUS AustraliaAustralia BelgiumBelgiumMexicoMexico Hong KongHong Kong UKUKCanadaCanada New ZealandNew Zealand ItalyItalyBrazilBrazil MalaysiaMalaysia FranceFrance
TaiwanTaiwan SpainSpainJapanJapan GermanyGermanyChinaChina (Others: Poland, Sweden,(Others: Poland, Sweden,
ThailandThailand Austria)Austria)
KoreaKoreaSingaporeSingapore(Others: Indonesia,(Others: Indonesia,Philippines, India)Philippines, India)
WE HELP YOU INVENT THE FUTURE.TM
Manufacturing SystemsManufacturing Systems
• Team Mission: Team Mission: Provide and support total Provide and support total solutions that optimize the product delivery solutions that optimize the product delivery business processes.business processes.
• Team’s Product and Services: Application Team’s Product and Services: Application Systems and I/T expertiseSystems and I/T expertise
WE HELP YOU INVENT THE FUTURE.TM
• ADC (Bar-coding) - FunctionalityADC (Bar-coding) - Functionality– Inventory Accuracy ImprovementInventory Accuracy Improvement– Automated Transactions for IM and WM Automated Transactions for IM and WM
modulesmodules– Operator entry of data for IM and WM Operator entry of data for IM and WM
transactionstransactions
MES - Inventory and DeliveryMES - Inventory and Delivery
WE HELP YOU INVENT THE FUTURE.TM
MES - Inventory and DeliveryMES - Inventory and Delivery
• Labeling Functionality (Americas only)Labeling Functionality (Americas only)– Provide for Label designProvide for Label design– Provide integration of SAP information onto Provide integration of SAP information onto
product labelproduct label– Provide “Print and Apply” for labeling of Provide “Print and Apply” for labeling of
materials on the plant floormaterials on the plant floor
WE HELP YOU INVENT THE FUTURE.TM
MES - Quality ManagementMES - Quality Management
• Quality ManagementQuality Management• Laboratory Information Management (LIMS) - Manage Laboratory Information Management (LIMS) - Manage
Sample tracking and test results for Quality Assurance Sample tracking and test results for Quality Assurance and Analytical laboratories and Analytical laboratories
• Provide automated interfaces to SAP for the QM Provide automated interfaces to SAP for the QM ModuleModule
• Provide automated interfaces to laboratory instruments Provide automated interfaces to laboratory instruments (Gas Chromatography, Viscometers, etc.)(Gas Chromatography, Viscometers, etc.)
WE HELP YOU INVENT THE FUTURE.TM
• OSIsoft PI System – OSIsoft PI System – – Collects “all” data from the process control Collects “all” data from the process control
systemssystems– Collects manually entered dataCollects manually entered data– Provides a tool set for analyzing the dataProvides a tool set for analyzing the data– Interface to SAP for activity and inventory Interface to SAP for activity and inventory
transactionstransactions
MES - Production ExecutionMES - Production Execution
WE HELP YOU INVENT THE FUTURE.TM
• Global systems – Global systems – – ADC - 8 servers serving 13 sites– 3500 usersADC - 8 servers serving 13 sites– 3500 users
– PI – 8 servers serving 13 sites – 650 usersPI – 8 servers serving 13 sites – 650 users
– LIMS – 7 servers serving 13 sites – 1200 usersLIMS – 7 servers serving 13 sites – 1200 users
– Totals – 23 servers –>5000 users – 3 major appsTotals – 23 servers –>5000 users – 3 major apps
• Other – Americas Labeling, SAP interfaces, Lab Other – Americas Labeling, SAP interfaces, Lab instrument interfaces, Safety Systems, etc.instrument interfaces, Safety Systems, etc.
MES - SummaryMES - Summary
WE HELP YOU INVENT THE FUTURE.TM
SAP-PCS Integration TeamSAP-PCS Integration Team
• Improve the effectiveness of the application of Improve the effectiveness of the application of SAP Business Process Workflow across Dow SAP Business Process Workflow across Dow Corning manufacturing sites. Ensure that the Corning manufacturing sites. Ensure that the Manufacturing & Production operational Manufacturing & Production operational information is appropriately integrated with the information is appropriately integrated with the supply chain and business process workflow.supply chain and business process workflow.
WE HELP YOU INVENT THE FUTURE.TM
• Efficient Manufacturing TransactionsEfficient Manufacturing Transactions– through automated routine tasks and coordinated activities through automated routine tasks and coordinated activities
through better communications.through better communications.• Integrated ProcessesIntegrated Processes
– vertically linking production within the manufacturing vertically linking production within the manufacturing processes.processes.
• Integrated Information SystemsIntegrated Information Systems– allowing for improved management decision making allowing for improved management decision making
through measured and monitored quality and cost control.through measured and monitored quality and cost control.• Reduced Product VariabilityReduced Product Variability
– in manufacturing, produce a specific material one way and in manufacturing, produce a specific material one way and only one way.only one way.
Business DriversBusiness Drivers
WE HELP YOU INVENT THE FUTURE.TM
What to IntegrateWhat to Integrate
COSTING
FORECASTING
PURCHASING INVENTORYMANAGEMENT
HUMAN RESOURCES
SCHEDULING
ORDERMANAGEMENTFINANCIALS
PRODUCTDEFINITION
ENTERPRISESAP R/3
QUALITYMANAGEMENT
DOCUMENT CONTROL
MATERIALUSAGE PRODUCT
TRACKING
PRODUCTIONHISTORY
RESOURCES MAINTENANCEMANAGEMENT
PROCESSANALYSIS
PRODUCTIONDISPATCHING
FACTORY FLOORMES
PRODUCT DEMAND, BILL OF MATERIALRECIPE, FORMULATION, RESOURCES,LABOR, INVENTORY STATUS, WORKINSTRUCTIONS
ORDER STATUS,COMPLETIONS,START/STOP TIMES, RESOURCE,LABOR, MATERIAL STATUS,ACTUAL BILL OF MATERIAL,PRODUCTION QUALITY DATA,SCRAP, WASTE
WE HELP YOU INVENT THE FUTURE.TM
Integration ArchitectureIntegration Architecture
Rlink
PROCESS INFORMATION SYSTEM
REAL TIMEDATABASE
HISTORIANPI - BATCH CALCULATIONENGINE
S P C
MANUALINPUT
DCSSCADALIMS
SAP R/3 SYSTEM
PP-PIPM QM
NETWORK
NETWORK
WE HELP YOU INVENT THE FUTURE.TM
Production Information FlowProduction Information Flow
• 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
• Schedule Information– Process Order/Batch Number
– Resource
– Proposed Quantity
– etc.
Rlink Layer
WE HELP YOU INVENT THE FUTURE.TM
Integration GoalsIntegration Goals
• Automate production recording Automate production recording
• Improve Data AccuracyImprove Data Accuracy
• Improve timeliness of data reportingImprove timeliness of data reporting
• Eliminate Production RecordersEliminate Production Recorders
• Reconcile physical and SAP inventory automaticallyReconcile physical and SAP inventory automatically
• Reduce Cost VariancesReduce Cost Variances
• E-Commerce supportE-Commerce support
WE HELP YOU INVENT THE FUTURE.TM
Integration ScenariosIntegration Scenarios
• DCS = Source of Data.DCS = Source of Data.
1.1.Continuous Processes.Continuous Processes.
2.2.Trailer Moves.Trailer Moves.
3.3.Mass Balance.Mass Balance.
4.4.Batch ProcessesBatch Processes
5.5.Material movementsMaterial movements
WE HELP YOU INVENT THE FUTURE.TM
Integration needIntegration needDow 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) ...“
WE HELP YOU INVENT THE FUTURE.TM
OSI Rlink TargetsOSI Rlink Targets
– Continuous processesContinuous processes
• for PO duration set start date and timefor PO duration set start date and time
• for reporting interval set as shift, day, hour, etc. for reporting interval set as shift, day, hour, etc.
– Batch processes w/out Batch EngineBatch processes w/out Batch Engine
• PI-ProcessBook/VB applications as campaign PI-ProcessBook/VB applications as campaign managermanager
– Batch processes with Batch EngineBatch processes with Batch Engine
• Foxboro IA Batch, Intellution iBatchFoxboro IA Batch, Intellution iBatch
WE HELP YOU INVENT THE FUTURE.TM
HOSTReactor
BlendStation
26 BatchCVD Reactors
Midland TCS
VirtualInventory
HCL to Midland
Polysilicon
WE HELP YOU INVENT THE FUTURE.TM
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
Procedure to Reconcile Physical Inventory and SAP Inventory Automatically.
WE HELP YOU INVENT THE FUTURE.TM
WE HELP YOU INVENT THE FUTURE.TM
WE HELP YOU INVENT THE FUTURE.TM
WE HELP YOU INVENT THE FUTURE.TM
WE HELP YOU INVENT THE FUTURE.TM
WE HELP YOU INVENT THE FUTURE.TM
Integration SpecificationIntegration Specification
• Makes Manufacturing document...Makes Manufacturing document...
– what their process iswhat their process is
– what parameters need to be captured for the what parameters need to be captured for the Business System and Business Recipe Business System and Business Recipe developmentdevelopment
WE HELP YOU INVENT THE FUTURE.TM
Integration Specification for each processIntegration Specification for each process
WE HELP YOU INVENT THE FUTURE.TM
WE HELP YOU INVENT THE FUTURE.TM
WE HELP YOU INVENT THE FUTURE.TM
Integration Skills for IntegrationIntegration Skills for Integration
Process ControlSkills
Process InformationSkills
Process IntegrationSkills
Business ProcessSkills
Batch EngineSkills
ManufacturingProcess Control
System:*Foxboro (DCS)*Intellution(SCADA)
ProcessInformation
System:*OSI PI (PIW)
Business ProcessControl System:
*SAP (ERP)
Batch Engine:*Foxboro-IA Batch*Intellution-iBatch
Standard:*ISA SP95
Standard:*ISA S88
Enterprise Domain
Execution Domain Integration Apps:*Foxboro BIS*OSI PS-RLink
Process ControlDomain
Integration SkillsRequired to
Integrate the PlantFloor to theEnterprise
WE HELP YOU INVENT THE FUTURE.TM
•What’s next?What’s next?
WE HELP YOU INVENT THE FUTURE.TM
OSI RlinkOSI Rlink
• RobustRobust
• ReliableReliable
• PowerfulPowerful
• FlexibleFlexible
• Perfect fitPerfect fit
• Always works!!!Always works!!!