DuPont MFG Integration to ERP

History, Description, and Value Capture – CISUG 9/10/07

Salvatore Grasso – Corporate Process Owner MFG/QM

Carmen DeVito – Program Manager DuPont SAP
 2

Enterprise Operations Management

“How do we take advantage of
what our businesses have in
common without losing of why
we are different?”
Common for all
“We identify, design, and build Businesses
80%
Common Configuration of
Best Practices and
Business Specific
Competitive Advantage
Practices.” Business Specific
20%

9/14/2007 DUPONT CONFIDENTIAL

 3

Initial standardization efforts were focused on business

processes supported by SAP. How could this be expanded to
include plant applications?

Level 4 Business Planning & Logistics

(ERP – eg SAP)

Manufacturing
Level 3 Operations Management
(Production, Maintenance,
Quality, Inventory Control)

Continuous Discrete Batch

Levels 2,1,0 Control Control Control
Systems Systems Systems

9/14/2007 DUPONT CONFIDENTIAL

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A benefit driven approach was used to identify which

business processes should be automated/integrated. The
business case was developed by answering 2 questions:

1. Is there a business case to connect SAP to the Plant Applications?

¾ Improve Productivity
¾ Reduce Inventory
¾ Improve Yield PI Sheet

¾ Enable Yield Accounting

¾ Improve Raw Material Utilization
¾ Improve Asset Utilization
¾ Improve Schedule Compliance
¾ Improve Delivery Performance
¾ Enable “Actual” Product Costing

2. How do I connect?
¾ Manual
¾ Automated
¾ Point-to-Point
¾ Architecture Based

9/14/2007 DUPONT CONFIDENTIAL

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Technical Architecture Overview MFG/QM

Enterprise
Integration: SAP R/3 4.x OMII Domain
BAPI / RFC/ IDOC ¾Centralized Design
¾Crossworlds ¾Centralized Build /
¾E*Gate Configuration Repository
¾Websphere SAP Adapter ¾Centralized Monitoring
¾MQSeries
¾….

Adapter

XML Messaging TIBCO Rendezvous Bus

Adapter. Adapter. Adapter Adapter

PIM - MES SF- MES LIMS MFG Apps Materials Mgmt

IP.21 Proficy, Legacy Blaze LIMS DataPass
Thermo/VG LIMS • Charting
• Blending
Optimizer
Shop Floor Controllers • Meridium
• …
• Honeywell • Rockwell
• ABB • Siemens
• Emerson • … Plant Environment

9/14/2007 DUPONT CONFIDENTIAL

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ISA’s S88 reference model was used to define

elements of the MFG application architecture.
Recipe Management Production Planning and Scheduling
Develop
Define Manage Batch
General General Schedule Enterprise/
MES
Recipe Recipe
Procedural Master Production Integration
Plant
Schedule
Element Manage Site Integration
Platform
Recipe
Define Process Management Architecture
Master Manage Collect Batch
Recipe Manage Master Manage and Process
Recipe Process Cell
Procedural Master Batches Cell
Resources Information
Element Recipe
Comments and Status Production
Information Information
Legacy Management
Unit Supervision
SAP PP-PI Acquire and Collect Batch Manage
Execute Manage Unit Data
Varies – Procedural
and Unit Batch History
Resources
MIMI/APO/Manugistics Elements Information
PIM/MES Comments and Status
Information
PAS/DCS
Process Control
BPS/PLC Execute
Execute
Equipment Collect Data
Basic Control
Phases

Control Comments and Status

Information
Data

Integration
Platform Physical Devices (Valves, Balances, etc.)

9/14/2007 DUPONT CONFIDENTIAL

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A number of businesses processes were automated/integrated. Standard SAP PP-PI

and ISA’s S95 reference model was used to create a re-useable “library” of messages.
SAP
Machine
User / APO Goods Issue is The Process The Process The Process Goods Receipt Control Recipe Inspection
Process Process The Process utilization is Batch is Posts a Goods Inspection
releases A Control Recipe posted and Order is updated Order is updated Order is updated is posted and and Process Lot Results
Orders are Orders are Order is updated recorded in updated with Movement Lot Results
Process is Generated inventory levels with phase with phase with phase inventory levels Order are are
created updated with phase start plant characteristics (Type 309) are Posted
Order are updated activity info activity info activity info are updated Closed Requested
maintenance

Process
Control Process Process Process Process Process Process Process Process Process Inspection
Process Process Message Inspection
Recipe Message Message Message Message Message Message Message Message Message Lot
Order Order (Process Lot Results
(Process (Phase (Goods (Phase (Phase (Phase (Goods (Meas. (Batch (Material Request
Download Upload Order
Order) Start) Issue) Activity) Partial) Finish) Receipt) Points) Chrctristcs ) Movement)
Close)

MES Material is
User / Finished Machine
Process Order Automated product / Batch transferred
utilization is
Process orders are Raw material Process Order characteristic (btw
is received by process starts Manufacturing processes execute semi-finished recorded (ie.
scheduled is consumed is closed s are batches, mat
IP.21 the process product is # of cuts,
order produced recorded #s, or
opens, etc.)
locations)
Finite Scheduler
Material Operator
CUSUM
sample is Lab Results takes and
Data is
sent to lab are archived confirms the
presented to
for quality in IP.21 corrective
an operator
assurance actions

DCS
Sample Quality CUSUM CUSUM
Login Results Data Feedback
User /
Automated
process starts Control and Monitor Manufacturing Process
manufacturing
process LIMS Results are
Material matched to
Operator Corrective
sample Lab Results the
identifies actions are
Information are entered in Requested
required archived in
entered in LIMS Inspection
PLCs process LIMS
LIMS Lot
Unit Controller Unit Controller Unit Controller change

DEVICES TALK/DATA
TALK RSCS TR RDTD CD TALK/DATA
TALK RS CSTR RDTD CD TALK/DATA
TALK RSCSTR RDTD CD TALK/ DATA
TALK RSCS TR RDTD CD TALK/DATA
TALK RS CS TR RDTD CD TALK/ DATA
TALK RS CSTR RD TD CD TALK/DAT
TALAK RSCS TR RDTD CD
Material
sample tested
in laboratory

SHOP LIMS
FLOOR
Sent Exactly Once per Control Recipe
Planning and Scheduling Process Lab Testing / Quality Mgmt Process Plant Maintenance Process
Sent At Least Once per Control Recipe
Process Order Execution Process Batch Characteristic Update Process Material -to-Material Movement Process
Sent as Needed

9/14/2007 DUPONT CONFIDENTIAL

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Scope of the implementation - Business Units & Plants

Niagara Falls, NY
-IP.21 Dordrecht, Netherlands
-IP.21 Wuppertal, Germany
-Legacy MES
Chambers Works, NJ -IP.21
-IP.21 IP.21
Buffalo, NY
Washington Works, WV -Legacy MES Chambers Works, NJ
-IP.21 (x3) -IP.21 -IP.21
SAP Landshut, Germany
-LIMS
Newark, DE -Legacy PCS
Memphis, TN Louisville, KY - SAP (x3)
-IP.21 -IP.21 Montbrison, France
Newark, DE Rubi, Spain -Recipe Optimizer
Beaumont, TX New Johnsonville, TN -Legacy PCS
-IP.21 -LIMS (x2) -Finite Scheduler
-IP.21
Newark, DE Kuan Yin, Taiwan
Edgemoor, DE
Laporte, TX -LIMS -IP.21
-IP.21
-IP.21
Corpus Christi, TX Fayetteville, NC
Delisle, MS
-IP.21 -IP.21 (x2)
-IP.21
Altamira, Mexico Publisher Subscriber Data DTT FLPR SURF DPC DCSE
-IP.21
Interface Name
Pontchartrain, LA Structure
-IP.21 Control Recipe Download SAP MES CTRL_REC X X X X X

MES SAP ZPI_PHST X X X X X

Phase Status Confirmation
MES SAP PI_PHACT X X X X
Phase Activity Update
Control Recipe Status MES SAP PI_CRST X X X X X

MES SAP Z_OT_MVT X X X X X

Goods Issue
MES SAP PI_PROD X X X
Goods Receipt – Planned
MES SAP Z_OT_MVT X
Goods Receipt – Unplanned
Batch Characteristics MES SAP Z_BT_CL X

MES SAP Z_OT_MVT X

CORP 3 DCSE 200 Material-to-Material Movement
Quality Results LIMS MES QL_RSLTS X X X

MES LIMS SMPL_LG X

In-Process Sample Login
MES LIMS SMPL_LG X
In-Process Sample Login and Quality Results
FLPR 200 DTT 805 CUSUM Data LIMS MES CUSUM_DT X

MES LIMS CUSUM_FB X

CUSUM Feedback
Measurement Points MES SAP PI_PMMD X X

SAP MES - X
Usage Decision
SURF 1022 DPC 100 SAP MES - X
Quality Notifications
Planned/Process Order Download SAP Scheduler - X

Scheduler SAP - X
Planned/Process Order Upload
Total Annual Publications: 2,300,000 approx.
SAP Optimizer - X
Inventory Download
Packaging/Labeling Download SAP Labeler - X

Labeler SAP - X
Packaging/Labeling Upload
LIMS SAP - X
Inspection Lot Request
SAP LIMS - X
Inspection Lot Download
Inspection Lot Results LIMS SAP - X

SAP LIMS - X
Inspection Lot Results Feedback

9/14/2007 DUPONT CONFIDENTIAL


Business Case – Payback was achieved by the time
the project was implemented.
Business Benefits
Productivity
¾ Automate “Feeding the Beast”
Inventory Management
¾ Raw Material Consumptions
¾ Finished goods visibility for order application
Asset Utilization
¾ Notification of equipment utilization to trigger
PM activities
¾ Visibility to actual shop floor production
¾ Plants continue to run during cutover and
planned/unplanned ERP outages
Activity-based Costing
¾ Actual differentiated cost by product
Support Manufacturing Six Sigma
¾ Enable inter/intra plant integration
¾ Facilitate sharing of information across the
organization
¾ Improve data accuracy across the plant
systems and SAP
9/14/2007 DUPONT CONFIDENTIAL
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IT Benefits
Development
¾ Productivity
¾ Enforce architecture and application
standardization
¾ Leverage pre-built adapters
¾ Standardize error handling, restart and recovery
functionality
Support
¾ Reduce upgrade / release testing costs
¾ Reduce on-going maintenance – standardized
parts to support and support productivity
Operations
¾ Support of 7/24 manufacturing operations
¾ Provide guaranteed message delivery by
eliminating single point of failure
¾ Decrease operating costs – monitoring, alarming
and recovery / restart
¾ Enhance scalability options (i.e., transaction
management and load balancing)

Key Lessons
Challenges
What should be automated / integrated?
How do you standardize given:
¾ Varying business requirements across business
units and plants
¾ Variety of legacy DCS / Plant Applications
Stringent Design / Build Requirements
¾ Highly Reliable
¾ High Throughput
¾ Highly Scalable and Interoperable
Stringent Support Requirements
¾ 7 x 24
¾ Global
¾ Short Response Times
9/14/2007 DUPONT CONFIDENTIAL
10
Successes
¾ Business benefits identify what to automate/integrate
¾ Total Cost of ownership drives automation/integration
approach
¾ Establish an Application/Technical Architecture vision by
leveraging industry standards - SAP PP-PI, ISA, SCOR,
etc
¾ Map products and tools to the Application/Technical
Architecture and use this to guide all new investments
¾ Create teams with resources who can represent all
business units and plants
¾ Front End Loading to Standardize, Standardize,
Standardize. We achieved:
¾ 75% common/shared messages
¾ 70% shared code / config in plant apps
¾ Identified key architecture considerations up front
¾ Used technical firsts to identify issues early
¾ Leveraged XML and publish / subscribe technologies to
enable other plants, apps, and SBUs to more easily
connect
¾ Leveraging existing Support Org & Processes where
possible
¾ Integrating / Modifying Support Processes where
required to support unique requirements associated with
manufacturing integration
Shop Floor to Top Floor:
Connecting Shop Floor People,
Processes, Devices and Data with SAP

Gil Rodriguez Salvatore Grasso

Acsis Inc DuPont
Company Overview

• Leader since 1996

• Solution Focus
– Integrated Supply Chain Solutions improving the flow of real-time
transactions and information from manufacturing and Distribution to SAP
systems.
• Customer Value
– Streamline processes and maximize execution efficiency
– Real-time access to shop floor data
• Target Markets:
– Chemical, CPG, Pharmaceutical
• Customers:
– 200+ of the most prestigious companies in our target markets
• Long-time SAP Partner
The Business Challenge

Companies have invested in

SAP to integrate their enterprise…

But, according to Gartner & AMR,

more than 90% of the shop floor devices
are not connected to the Enterprise Resource Planning
Systems
…and process automation and people development to drive efficiency
in manufacturing and warehouse operations

©2006 Acsis, Inc.

Salvatore Grasso
Integrated Acsis – SAP Solutions Architecture

CPG Pharmaceuticals Chemical

Trading
e-Pedigree Partner
Shop Floor Container
RFID ASN Data Xchange Automation Tracking Solutions

Business Applications Analytics

Business
XI
R/3 SCM PLM
RFID Analytics Solutions
Enterprise Plant
Label Mgmt Manager Netweaver BI

MES

Lab
Systems Transaction
Plant Management
Historian xMII Auto-ID Infrastructure
Maintenance
Systems
Manufacturing xDDI Distribution
Line Manager by Acsis
Line Manager Process
Automation
& Device
Operator Label RFID Tag Open-Air Handheld Handheld Stretch Shipping
Management
VMU Palletizer
Console Printer Applicator Encoder RFID Barcode Wrap Dock Door
Mobile Devices
More than 1000 transactions
automated
• Purchasing • Picking • Auto-ID
– Create Purchase Order – Create Pick List Infrastructure
– Advanced Shipment – FIFO Bin Display – Pick
Notice – Shipment Display – Pack
– Raw Material Labeling – Bin Status Lookup – Move
– Goods Issue – Ship

• Receiving • Inventory • Warehouse

– Goods Receipt Management Management
– Directed / Undirected – Stock Overview – Maintain Shift
Putaway Information
– Cycle Count
– Transfer Orders
– Inventory Lookup
– Putaway
• Manufacturing – Pallet Inventory
– Bin-to-Bin Transfer
– Consume Raw Material – Physical Inventory
• Batch Controlled
• Cost Center • Label Management • Shipping
• Back flush – Item – Create Delivery
– Divert product – Case – Pick
– Move product – Pallet – Pack
– Production Confirmation – Container – Load
– RFID – Confirm Delivery
– Report Work-in-Progress
– Barcode – Unpick Delivery
– Report Production
– Ship Verification
– Report Scrap
– Pick to Stage
Thank You

Contact Info:
Gil Rodriguez
grodriguez@acsisinc.com