1 / 37

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

alvis
Télécharger la présentation

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

An Image/Link below is provided (as is) to download presentation Download Policy: Content on the Website is provided to you AS IS for your information and personal use and may not be sold / licensed / shared on other websites without getting consent from its author. Content is provided to you AS IS for your information and personal use only. Download presentation by click this link. While downloading, if for some reason you are not able to download a presentation, the publisher may have deleted the file from their server. During download, if you can't get a presentation, the file might be deleted by the publisher.

E N D

Presentation Transcript

  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

More Related