we help you invent the future. tm [email protected]

WE HELP YOU INVENT THE FUTURE.TM

[email protected]


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


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


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


SAP R/3 ARCHITECTURESAP R/3 ARCHITECTURE


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


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


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


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)


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


• 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


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


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.)


• 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


• 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


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.


• 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


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


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


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


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


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


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) ...“


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


HOSTReactor

BlendStation

26 BatchCVD Reactors

Midland TCS

VirtualInventory

HCL to Midland

Polysilicon


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.


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


Integration Specification for each processIntegration Specification for each process


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


•What’s next?What’s next?


OSI RlinkOSI Rlink

• RobustRobust

• ReliableReliable

• PowerfulPowerful

• FlexibleFlexible

• Perfect fitPerfect fit

• Always works!!!Always works!!!

we help you invent the future. tm [email protected]

Documents

sap plantssites

tm sap r3 architecture

tm sap r3 implemenation

tm sap modules demand

concurrent users

double byte users

aa fi slide

global sales finance