1 manufacturing systems integration at. 2 ma hanna yesterday headquartered in cleveland, ohio...

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Manufacturing Systems

Integration at

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MA Hanna YesterdayMA 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 YesterdayGeon Yesterday Headquartered in Avon Lake, Ohio

Employs 3,100 people worldwide World’s largest producer of vinyl (PVC)

compounds $ 820 Million

North America’s 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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StrategyStrategyStrategyStrategy

PPoollyymmeerrss

AAddddiittiivveess

Appliances &Business Equipment

PackagingPackaging

ConsumerConsumerProductsProducts

CCoonnssuummeerrss

Communications/Electronics

DDeessiiggnneerr//AAsssseemmbblleerr

CCOOMMPPOOUUNNDDEERRSS

PPRROOCCEESSSSOORRSS

Service & Service & DistributionDistribution

Building Materials

Automotive

Packaging

Consumer Products

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Manufacturing Integration HistoryManual Plant pilot

•Scope & Design•User Views

Automated Plant Project•Scope & Design, Data Views

Lessons & ExperiencesQuestions?

Manufacturing Systems

Integration at

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

Su

pp

lier(

s)

Cu

stom

er(s)

Sell-Service Design-Make Source Logistics-Delivery Close Sale

Receive Payment

Order Fulfillment

ProcurementManufacturingOrder Processing

Planning

In 1988, we began our Computer Integrated Enterprise vision by attempting to simplify,

automate and integrate our internal processes

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Corporate

Process Model(SCADA)

Manufacturing Execution

System (MES) -PROCESS/1Inventory

Management

Procurement

Planning

Forecasting/PlanningSystem

Order EntrySystem

FinancialSystem

FG / ShippingSystem

Raw MaterialInventorySystem

Run TrackingProcess Control

GENERAL STORE

Distribution

Plant

Line

SID

LIMSCHAMPS

NTNT

Geon’s Computing Environment

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High Level Information Flow

PREPARE FOR PRODUCTION

RUNS

PREPARE FOR PRODUCTION

RUNS

EXECUTE PRODUCTION

RUNS

EXECUTE PRODUCTION

RUNS

ANALYZE PRODUCTION

RESULTS

ANALYZE PRODUCTION

RESULTS

INPUTS KEY FUNCTIONS

OUTPUTS/ INPUTS

KEY FUNCTIONS

OUTPUTS/ INPUTS

KEY FUNCTIONS

OUTPUTS

MATERIAL DELIVERIES

PRODUCTION SCHEDULE/

BOM

SPC/SQC ANALYSIS RESULTS

RECIPE ADJUSTMENTS

PREPARE LINE RECIPE PACKET

ORDER, RECEIVE, AND

BAR-CODE MATERIALS

SET UP SPC SPECS

LOT SPECIFIC RECIPE PACKET

SPC SPECS

BAR-CODED RAW

MATERIALS

PICK RAW MATERIALS FOR

3RD & 4TH FLOOR

MAKE-UP BULK, MASTER BATCH AND HAND-ADD

MATERIALS

EXECUTE, CONTROL, AND MONITOR RUN

TRACK ACTUAL RUN

PERFORMANCE

RUN HISTORY:

•PRODUCTION RUN AUDIT TRAIL

•MATERIAL USAGE

•FINISHED GOODS PRODUCTION

•RUN START/STOP TIMES

•DOWNTIME EVENTS

•SALVAGE

•PROCESS VARIABLES

MATERIAL PERFORMANCE VIEW/UPDATE

ANALYZE RUN PERFORMANCE

PERFORM SQC ANALYSIS

RUN PERFORMANCE

MEASURES

PRODUCTION RUN AUDIT

TRAIL

SPC/SQC ANALYSIS RESULTS

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The Manufacturing Systems Journey

EXECUTEPRODUCTION

RUNS

CONTINUOUSIMPROVEMENT

PREPAREPRODUCTION

RUNS

ANALYZEPRODUCTION

RUNS

INCREASE QUALITYAND CONSISTENCY

COMPETITIVECOSTS

CUSTOMERRESPONSIVENESS

SIMPLIFICATION

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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

CorporatePlant

SAP

MDS

OSI PI

MDEProcess Ctl

LRM/PRM

DW• EIS• MDS• Other

All Geon Sites

• EPM• P1

• DA• DH/DHE• SQC

Mfg. Systems Strategy Study

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Mfg. study revealed several things:

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

Mfg. Systems Strategy Study

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Manufacturing Integration HistoryManual Plant pilot

•Scope & Design•User Views

Automated Plant Project•Scope & Design•User Views

Lessons & ExperiencesQuestions?

Manufacturing Systems

Integration at

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CorporatePlant

SAP

MDS

OSI PI

MDEProcess Ctl

LRM/PRM

DW• EIS• MDS• Other

All Geon Sites

• EPM• P1

• DA• DH/DHE• SQC

OSI RLink Pilot

At Farmingdale PlantAt Farmingdale Plant

Prove OSI PI link to SAPProve OSI PI link to SAP

•Manual Data Manual Data entry to OSI PIentry to OSI PI

•Automatic interface Automatic interface to SAP via OSI RLinkto SAP via OSI RLink

•Ability to analyze Ability to analyze data in OSI PIdata in OSI PI

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BOXBOX To BulkTo Bulk

MASTER BATCH MATERIAL

BULK MATERIAL

HAND ADD AND

COLOR BLEND MATERIAL

Two distinct Orders

SAP Master Recipe Design

Order 1 Order 2

Each Order:

•one operation

•one phase

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Standard PSRLink Interface

for Informational Data

AMAT

AMATP01

APHASE

AORD

APHAR

SAP R/3

PP-PI

PSRLINK

PI

Process Instructions

Control Recipes

SAP PP-PI Process Instructions/Messages

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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

SAP PP-PI Process Instructions/Messages

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Standard PSRLink Interface

for Process Data Request

ACONS

APROD

APHCON

ACRST

SAP R/3

PP-PI

PSRLINK

PI

Process Instructions

Control Recipes

Process Messages

SAP PP-PI Process Instructions/Messages

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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

SAP PP-PI Process Instructions/Messages

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SAP Order Process Instructions

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SAP Order Process Instructions in RLink

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

X Resin1 250#

X ImpMod2 150#

X Stab3 100#

X Pigment4 50#

X Resin1 250#

X ImpMod2 150#

X Stab3 100#

X Pigment4 50#

X Resin1 230#

X ImpMod2 140#

X Stab3 110#

X Pigment5 60#

1st Conf.Resin1, 250ImpMod2, 150Stab3, 100Pigment4, 50

2nd Conf.Resin1, 480ImpMod2, 290Stab3, 210Pigment4, 50Pigment5, 60

Phase start Phase confirmation Phase confirmation

RLink Translation Method

Time

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Manufacturing Integration HistoryManual Plant pilot

•Scope & Design•User Views

Automated Plant Project•Scope & Design, Data Views

Lessons & ExperiencesQuestions?

Manufacturing Systems

Integration at

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Starting Recipe & PhaseStarting Recipe & Phase

Process Orders are sorted byStart Date and mimic the ZSCH screen in SAP which

is still used to schedule production

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Blender Production ReportingBlender Production Reporting

Enter the correct Batch numbers for all the RM you used with a drop down!

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Blender Batch Process DataBlender Batch Process Data

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Compound Production ReportingCompound Production Reporting

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Compound Cont. Process DataCompound Cont. Process Data

You can quickly see process data trends right on the screen

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User Developed Custom AppsUser Developed Custom Apps

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User Developed Custom AppsUser Developed Custom Apps

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User Developed Custom AppsUser Developed Custom Apps

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Manufacturing Integration HistoryManual Plant pilot

•Scope & Design•User Views

Automated Plant Project•Scope & Design, Data Views

Lessons & ExperiencesQuestions?

Manufacturing Systems

Integration at

32

CorporatePlant

SAP

MDS

OSI PI

MDEProcess Ctl

LRM/PRM

DW• EIS• MDS• Other

All Geon Sites

• EPM• P1

• DA• DH/DHE• SQC

on Vaxon Vax

The Next Step

At a Legacy PlantAt a Legacy Plant

Prove No Process/1Prove No Process/1

•Automatic PCS Automatic PCS interface to OSI interface to OSI PI/RLinkPI/RLink

•Proven Auto Proven Auto interface to SAP via interface to SAP via OSI RLinkOSI RLink

•Ability to analyze Ability to analyze data in OSI PIdata in OSI PI

•Interface OSI PI/RLINK Interface OSI PI/RLINK with Vax LRM/PRMwith Vax LRM/PRM

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As-Is Process Model InterfacesAs-Is Process Model Interfaces

SAPSAP

LIMSLIMS

P1P1 PIPI

ProvoxProvox

ModelModel

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 Transfer:part of 042)

B- PGRTR702 (Production: Part of PGRTR710)

B- PGRTR800 (Vendor Lot Modification: Consumption)

B- PGRTR716 (MB/CB Reconciliation)A B

C

D

C- PGRTR703 (Submitted by PRM at Campaign Completion)

C- PGLIM703 (LIMS Campaign Close)

C- PGLIM702 (Sends PMU’s to LIMS)

D- PGTR705 (LIMS Grading)

Process Control

PGRTR706 (R-Mail Grade Change)

Question:

*PGPCM098 (Global Section Backup-BMAT)

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New Process Model/RLink/SAP InterfacesNew Process Model/RLink/SAP Interfaces

SAPSAP

LIMSLIMS

PIPI

ProvoxProvox

ModelModel

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

AC

D

These Are Model and LIMS Specific:

C- PGRTR703 (Submitted by PRM at Campaign Completion)

C- PGLIM703 (LIMS Campaign Close)

C- PGLIM702 (Sends PMU’s to LIMS)

D- PGTR705 (LIMS Grading)

PGPCM098 (Global Section Backup:Model Specific)

Process Control

E/IF

Existing ProgramsExisting Programs

Rlink ServerRlink Server

SQLVB

B/I

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BOXBOX To BulkTo Bulk

MASTER BATCH MATERIAL

BULK MATERIAL

HAND ADD AND

COLOR BLEND MATERIAL

Mixer

Phase

Extrusion

Phase

Packaging

Phase

Each Order has One Operation

SAP Master Recipe Design

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SAP Order Operations & Phases

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Standard PSRLink Interface

for Informational Data

AMAT

AMATP01

APHASE

AORD

SAP R/3

PP-PI

PSRLINK

PI

Process Instructions

Control Recipes

SAP PP-PI Process Instructions/Messages

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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

SAP PP-PI Process Instructions/Messages

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Standard PSRLink Interface

for Process Data Request

ACONS

APROD

APHCON

ACRST

SAP R/3

PP-PI

PSRLINK

PI

Process Instructions

Control Recipes

Process Messages

SAP PP-PI Process Instructions/Messages

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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

SAP PP-PI Process Instructions/Messages

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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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Tags RecipeMat’lBatchQty

X Rcp1 Resin Resin1 250#

X Rcp1 ImpMod ImpMod2 150#

X Rcp1 Stab Stab3 100#

X Rcp1 Pigment Pigment4 50#

X Rcp1 Resin Resin1 250#

X Rcp1 ImpMod ImpMod2 150#

X Rcp1 Stab Stab3 100#

X Rcp1 Pigment Pigment4 50#

X Rcp1 Resin Resin1 230#

X Rcp1 ImpMod ImpMod2 140#

X Rcp1 Stab Stab3 110#

X Rcp1 Pigment Pigment5 60#

1st Conf.Rcp1 Rcp1 Rcp1 Rcp1Resin ImpMod Stab PigmentResin1 ImpMod2 Stab3 Pigment4250 150 100 50

Phase start Phase confirmation Phase confirmation

Tags RecipeMat’lBatchQty

2nd Conf.Rcp1 Rcp1 Rcp1 Rcp1 Rcp1Resin ImpMod Stab Pigment PigmentResin1 ImpMod2 Stab3 Pigment4 Pigment5480 290 210 50 60

RLink Translation Method

Time

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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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Standard PSRLink Interface

for Unsolicited Process Data

ACONS

APROD

MATRANS1

MATRANS2

LINEVENT

SAP R/3

PP-PI

PSRLINK

PI

SAP PP-PI Process Instructions/Messages

Process Messages

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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

SAP PP-PI Process Instructions/Messages

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RLink Interface data in PI

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RLink Alarming via PI tags

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Manufacturing Integration HistoryManual Plant pilot

•Scope & Design•User Views

Automated Plant Project•Scope & Design, Data Views

Lessons & ExperiencesQuestions?

Manufacturing Systems

Integration at

54

Manufacturing Integration HistoryManual Plant pilot

•Scope & Design•User Views

Automated Plant Project•Scope & Design, Data Views

Lessons & ExperiencesQuestions?

Manufacturing Systems

Integration at