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2001 OSI Software Users Conference 9 th - 13 th April 2001

2001 OSI Software Users Conference 9 th - 13 th April 2001. Synchronizing SAP with Plant floor Operations. Joël Bourbonnais (Pétromont) Ghislain Cadoret (SmartQuest) Martin Jetté (OSISoft Canada). Agenda. Company Project and schedule Key objectives

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2001 OSI Software Users Conference 9 th - 13 th April 2001

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  1. 2001 OSI Software Users Conference9th - 13th April2001

  2. Synchronizing SAP with Plant floor Operations Joël Bourbonnais (Pétromont) Ghislain Cadoret (SmartQuest) Martin Jetté (OSISoft Canada)

  3. Agenda • Company • Project and schedule • Key objectives • Goals pursued through a commercial interface • Challenges • Why Rlink • Functional and Technical design • Key success factors and Opportunities for improvement • Questions & comments

  4. Company • Pétromont Inc. is a limited partnership equally owned by Union Carbide Canada Inc. (which is now owned by DOW Chemicals) and Éthylec Inc. (owned by Société Générale de Financement) • Pétromont manufacture high-density polyethylene (UNIPOL® technology) and basic petrochemicals (Olefins) • Established in 1980 • Average annual sales: 500M$ CND • 450 employees

  5. Facilities • Montréal facility: Production of high-density polyethylene • 265 kty HDPE • Varennes facility: Production of basic petrochemicals (Olefins) • 285 kty ethylene • 135 kty propylene • co-products

  6. LePep Project • Phase approach • Phase I: Expenses (MM Purchasing, FI-CO, QM raw materials) • Phase II: Revenues (SD, PP-PI, QM, CO-PA, RLink) • Phase III (future): Others (PM, HR, etc.)

  7. Schedule

  8. Key objectives • System accepted and used by operators • single user interface • keep existing screen layout when applicable • Single database for all product information (Product definition, specifications, instructions, operating parameters, etc.) • Keep It Simple Stupid (Model K) • Reduce number of different systems

  9. Up to 10 business systems removed

  10. Goals pursued through a commercial interface • Insure data validity by minimizing manual data manipulations • Provide a convivial GUI (avoid unfriendly SAP menus) • Provide a commercial interface that will evolve over time with SAP and PI/PHD historians • Insure timely and reliable bi-directional data routing:- QM data- Material consumptions- Production confirmation- Operating windows • Provide troubleshooting capabilities

  11. Challenges • An interface was not planned – no budget • Honeywell environment • UDA availability • Tight Schedule • RLink Complexity

  12. Why Rlink • Industry vision to synchronize plant floor operations with business system through a commercial package that will evolve over time • Proven solution since 1996 • Flexibility to add new functionality like lab results • OSI Software is well positioned for this type of product • Includes operating parameters functionality • Includes phase interruption functionality • Operational analysis tools like PI-Batch, etc.

  13. Functional design - POLYETHYLENE Level 3 – Enterprise Systems Transaction based (Months, Days, Hours) Level 2 – Manufacturing systems Near real-time, data-event driven Level 1 – Process Controls Real-Time (Seconds & Milliseconds), Critical

  14. Level 3 – Enterprise Systems Transaction based (Months, Days, Hours) MIMI Manual Input to SAP Planning SGE SAP R/3 PP-PI Not connected tank raw inventory Tank and pipe- line inventory Level 2 – Manufacturing systems Near real-time, data-event driven Quantity and du- ration confirmation Process Order Aiguilleur VB Input screen for not connected Tank inventory Commercial I/F not planned Quantities consu- med and produced for the last 24hrs RLINK (OSI) HONEYWELL PHD (Process Historian Data) Level 1 – Process Controls Real-Time (Seconds & Milliseconds), Critical Raw inventory Functional design - OLEFINES

  15. Process Order Structure

  16. Recipe and BOM Structure “K”

  17. Interface Design DCS - SAP

  18. Data Source • Automatic from field instruments through “Rlink Totalizer” • PHD Formula to track the purge bin quantity • Manual entries for Catalyst and solid additives • Hopper car confirmation through direct link to the scale

  19. Data to Exchange SAP Connecting SAP with plant floor: • Data from Process: - Recipe and phases status changes (with possibility of interruptions) - Feedstock consumptions - Production confirmation • Data from SAP: - Process Orders to manufacture - Bill of materials - Lab results - Operating conditions (formula) RLINK PI PHD DCS

  20. Communication Interfaces • RLINK only communicates with PI Historian and SAP • Pétromont is using PHD Historian (from Honeywell) and PHD is well deployed over both plants • PI-UDA, the connector between PI and PHD, allows us to see PI as a « black box » between RLINK and PHD

  21. PI-PHD vs PI-UDA Interfaces Today: • PI-PHD: Only allow sequential exchanges between PI and PHD. Still need to archive in PI. • PI-UDA: Allow out of order insertion in PHD. Only archiving in PHD (except for PI-Batch) PI- Data Archive PI-PHD PI-PHD PHD Montréal PHD Varennes Futur (2001): PI-UDS PI-UDA PI-UDA PHD Montréal PHD Varennes

  22. Network Architecture

  23. Operator Interface: OperUnipol • A VB application developed for operators to interact with RLINK and SGE (Hopper Car Managing System). • Prevents operators from using SAP GUI... • ProcessBook not chosen in order to have a simple application, without having to deploy ProcessBook. • A « read-only » version is used by specialists and management to monitor progress of P.O. in real time.

  24. OperUnipol - Main Screen

  25. OperUnipol - Status Display

  26. OperUnipol - Lot Checking

  27. OperUnipol - P.O. Selection

  28. OperUnipol - Hopper Car Loading

  29. OperUnipol - Manual Entries

  30. DCS Display - Operating parameters

  31. QM Results

  32. Results • Spontaneous positive comments from operators!!! • Integration of operating windows with the product • Better Integration between the Lab and the operators • Up-time is 99%. 1-2 months to handle unplanned exceptions but now very stable environment • Still some problems with instrumentation accuracy • Smooth “go live” without disasters • Takes 2 days to close the period instead of 4-5 days

  33. Key success factors • Key representative from the plant operations • Decisions (software, system architecture, etc.) based on real workable solution (field tested) • Screen design (idiot proof) • Person knowing both worlds SAP and Shop floor operations • Commitment from the board (rapid decision) • Plant readiness • “Train the trainer” approach

  34. Opportunities for improvement • Need more time from RLink expert during development • Increase knowledge transfer from consultants before they leave

  35. RLink opportunities for improvements • Enhance RLink documentation (stored procedure, etc.) • Be able to report raw material consumption for the same material from different equipments for a phase • Have a more structured Rlink training • Be notified when new version/patch are available

  36. Next Steps • Upgrade SAP to 4.6 • Phase III ( PM, HR, PM-Rlink ?, etc.) • Install UDS and UDA • Eliminate manual entries

  37. Questions & Comments

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