CHANGING MANUFACTURING Hyla Soft projects and Consulting activity on Siemens Manufacturing Operation Management Systems
www.hylasoft.com
INTRODUCTION Hyla Soft, a global company able to draw on the resources of highly skilled technical consultants, delivers top of the line solutions and products to clients across industries worldwide.
In this document, a list of significant customer cases is described to underline our specific skills and capabilities.
With a focus on the business of manufacturing, Hyla Soft provides technology solutions, end to end, across diverse industry sectors including Automotive, Aerospace, Discrete Manufacturing, Food and Beverage, Bio-Science, CPG, Pharma, Oil and Gas, Energy and Utilities, and Government.
The first section is dedicated to some of the major turn key projects developed with Siemens Simatic IT, the second to projects carried out as Siemens sub-contractor.
Hyla Soft integrates manufacturing IT solutions applying bestpractice industry standards, knowledge and expertise that give our clients a competitive edge in access to real-time data and information from the shop floor to executive management levels. This integration offers real, tangible benefits for management of the manufacturing, quality control, engineering and supply chain processes. As both a solution innovator and integrator and with direct access to a network of world-class, global partners, Hyla Soft can offer products and solutions using the best software available in the industry.
The third section includes our references for Siemens Simatic IT Intelligence Suite, which is the module built for Manufacturing Intelligence purposes, that enables standardization and optimization of reporting processes both for single plants and cross plants. The fourth section describes projects we’ve been involved in as consultants. Hyla Soft MES Simatic IT experts number more than 140, consisting of 60% working as software engineers and analysts at different levels of seniority and 40% acting as project managers, technical leaders and process analysts on projects.
INDEX 1.
Turn Key Projects
4
2.
Work packages as a Siemens sub-contractor
7
3.
Manufacturing Intelligence Projects with Simatic IT
14
4.
Consulting Activity in Siemens Projects
16
3
1. TURN KEY PROJECTS Case #1: Whirlpool Europe Functional Scope
Order Management, Material Management, ERP Interface, and Lean Manufacturing Plant for every part, Shopping List. Introduction of an MES standard Whirlpool Solution within all key European manufacturing plants enabling a Material Management Strategy (MMS) component and capability of interfacing with a newly rolled out SAP manufacturing system. Whirlpool is now evaluating whether to pilot the OEE and Manufacturing Intelligence Functionality of SIMATIC IT.
Challenges
Coordination between the manufacturing transformation strategy and MES system design and the implementation roadmap.
SIMATIC IT Functionality
ERP Integration, Genealogy, Tracking and Tracing.
Location and Scope
Europe - Italy (3), Poland (1), Czech Republic (1), France (1) Number of users: 80 Types: Operator, Supervisor, Administrator.
On/Offshore Resource Split Onshore, Hyla Soft (Europe) –100%.
Language Skills English
Knowledge Transfer Activities
Engineering and internal support by training to key users and system administrators.
Key Performance Metric Used
Conformance to plan, conformance to cost, adherence to the SAP roll out schedule.
Project Management
The Hyla Soft project team, guided by a Program Manager, coordinated the PMs in dedicated streams of projects/sites. A joint steering committee involving Whirpool Management (IT and Operations), PMs and Hyla Soft Management (Technical Delivery, Account Management and General Manager) was established. Weekly and monthly reviews of project performance were conducted to keep the customer current with the development progress.
Support Model
Hyla Soft (Italy) coordinated and delivered the project using the resources of its European offices using a distribution delivery approach with remote software development. First tier maintenance and support was performed on site and remotely.
4
#2 Case #2: TASNEE, Saudi Arabia Functional Scope
A Manufacturing Execution System for a logistics management system with the goal of providing the following primary functions: Material Handling
Support Model
Hyla Soft delivered the project using the resources of its European Offices. System maintenance and support is now performed by Tasnee.
On/Offshore Resource Split
SAP integration
Onshore, Hyla Soft (Europe) – 100%
DCS/PLC integration
Language Skills
Monitoring silos/farm status (lot/grade/quantity) Monitoring incoming material transactions from control system DCS/PLC Tracking of truck traffic and operational status within the plant Monitoring of the status of each palletizing line Monitoring of the status of each loading bay Enabling the silo unloading/silo washing/silo drying, removing the consent to load to the upstream systems Generation of load orders (bagging/bulk loading) and the relevant reports.
Challenges
Coordination of project changes with other companies involved in the project.
English
Key Performance Metric Used Conformance to plan, conformance to cost.
Project Management
Tasnee set the schedule based on an agreed project plan and Hyla Soft performed the work needed to fulfill the project milestone requirements. Once completed, Hyla Soft reported the current status and the next steps agreed back to the project team. The first major milestone was producing User Requirement Specifications (URS) and the second major milestone was producing the Detailed Design Document. The last milestone was Development and Configuration. After a successful SAT, Hyla Soft trained users and the system became “go live”. A support structure was also set up among the plant, Tasnee and Hyla Soft.
SIMATIC IT Functionality
ERP Integration, Secondary Management, Genealogy, Load Out.
Location and Scope Kingdom of Saudi Arabia
5
#3 Case #3: NATPET, Saudi Arabia Functional Scope
A Plant Information Management System (PIMS) and Laboratory Management System (LIMS) to provide technical support including: Plant monitoring Decision support system for plant activities Maximizing equipment efficiency to increase plant through-put) Constraint control related to plant safety Long term archive capability
Primary functions of the PIMS System: Supervision of process data variables Supervision of production parameters KPI monitoring
Challenges
Project schedule coordination with other companies involved in the project. SIMATIC IT Functionality: Operation Information Management (SIMATIC IT Framework) Laboratory Information (SIMATIC IT Unilab) Quality Management (SIMATIC IT Unilab) Equipment Monitoring (SIMATIC IT Historian – PPA Plant performance Analyzer/OEE) Personnel Resources Management (SIMATIC IT PRM and framework) Lot and report tracing, inventory of raw materials, finished products and intermediate products (SIMATIC IT production suite – report manager)
Location and Scope
Maintaining operator log book
Kingdom of Saudi Arabia
Inventory control and reporting
Support Model
Primary functions of the LIMS System: Laboratory management Sample, login and tracking
Live support
On/Offshore Resource Split Onshore, Hyla Soft (Europe) – 100%
Language Skills
Barcode reading and printing
English
SQC statistical quality control
Data Protection Safeguards
Bi-directional link with (through SIMATIC IT framework) a Distributed Control System
Personal NDA procedures for all Technimont and Hyla Soft employees were applied.
Key Performance Metric Used Conformance to plan, conformance to cost.
Project Management
Natpet defined the project plan schedule and Hyla Soft performed the activities requested. Status of the project was supervised by the customer with conference calls each week.
6
2. WORK PACKAGES AS SIEMENS SUB-CONTRACTOR Case #4: Riello Burners Functional Scope
Hardware automation revamping with a review of functionality implemented in the current Simatic IT Production Suite (v5.1) and MES Application built on it. Automation and integration of test instruments is the core of this project. The use of Communication Manager (Hyla Soft’s MES-Shop Floor interface Middleware) to decouple MES “languages and speed” and Shop Floor is used to accomplish this. SIMATIC IT Functionality: Plant Data Model (SIMATIC IT Production modeler) Operation Information Management (SIMATIC IT Framework) Production Order Management (SIMATIC IT POM) Material Management (SIMATIC IT MM) Routing Management (SIMATIC IT PDefM)
Location and Scope Italy
Support Model Live support
On/Offshore Resource Split Onshore, Hyla Soft (Europe) – 100%
Language Skills Italian
Key Performance Metric Used Conformance to plan, conformance to cost.
Project Management
Schedule defined by Atos with Hyla Soft performing the activities requested. Status of the project was supervised by Atos with weekly conference calls.
Challenges
Project schedule coordination with other companies involved in the project.
7
#5 Case #5: Kraft Foods (Cadbury) Functional Scope
Order Management, Material Management, ERP Interface; Pallet Management, Label Management. Siemens developed a solution for Kraft Cadbury handling palletizing and labeling which was standardized for all plants involved in the first phase of the project. Hyla Soft was commissioned by Siemens to configure and deploy the solution for 4 plants in France and to define a test system in which plants with the same functionality as those of the British, French and Spanish plants, are implemented on the virtual platform. Hyla Soft was also subcontracted to implement of several change requests by Kraft.
Challenges
An optimized remote delivery model.
On/Offshore Resource Split Onshore, Hyla Soft (Europe) – 100%
Language Skills English
Key Performance Metric Used Conformance to plan, conformance to cost.
Project Management
A Project Manager coordinating with a Project Leader (Senior Business Analyst) and several Software Engineers. Weekly reviews of the project performance were performed with Siemens and included review calls/webinars with the customer.
SIMATIC IT Functionality
ERP Integration, Production Order Management, Material Management, Secondary Management, Reporting.
Location and Scope
France: 4 sites and 3 test sites Users: Administrator, Super User, Operator User, Line Analyst
Support Model
Project team supplied by Hyla Soft, Italy as a Siemens subcontractor.
8
#6 Case #6: Large Chemical Fibers Manufacturer Functional Scope
ERP Integration, Order Management, Material Management & Genealogy, Product Definition, OEE, Quality. Definition and implementation of new MES Functionality strongly connected to business processes.
Challenges
Multi-company project management, distributed project teams management.
SIMATIC IT Functionality
Production Order Management, Material Management, OEE, PM, Production Definition Management.
Language Skills English
Key Performance Metric Used
Conformance to plan, conformance to cost, adherence to the SAP roll out schedule.
Project Management
Internal project team guided by a Siemens Project Manager coordinating with a Hyla Soft Technical Leader. The work package project team was guided by a Hyla Soft Project Manager. Monthly meetings and conference calls to review project performance.
Location and Scope
Netherlands, U.S.A. (1 site each) Number of users: 50 Types: Plant Manager, Shift Supervisor, Quality Manager, Quality Operator
Support Model
Delivery of turnkey packages using the resources of Hyla SoftEurope and US. Hyla Soft resources outsourced in Siemens were deeply involved in the development and deployment of the solution (80% of the team).
On/Offshore Resource Split Offshore, Hyla Soft (USA) – 60%, Onshore, Hyla Soft (Europe) – 40%
9
#7 Case #7: FIAT Group Automobiles, FIASA Functional Scope
Using a configurable and flexible MES platform, provide support to upgrade and standardize current management systems for press units. Roll out activities in Italy and Brazil. Our solution, based on Simatic IT with a modular structure covering and integrating data management, incoming spare parts management, warehouse management, OEE, shipping, ERP interfaces was used. Graphic user interfaces, available through a web application and specifically designed and profiled for different categories of operators were used. Benefits identified are standardization and re-engineering of different processes, decreasing operational costs and increased MES functional coverage when compared to current systems in use.
On/Offshore Resource Split Onshore Hyla Soft (Europe) – 100%
Language Skills English
Project Management
Internal project team guided by a Siemens Project Manager coordinating with a Hyla Soft Technical Leader. The work package project team was guided by a Hyla Soft Project Manager. Monthly meetings and conference calls to review project performance.
Challenges
Multi-company project management, distributed project teams management.
SIMATIC IT Functionality
Production Order Management, Material Management, OEE, PM, Production Definition Management, Material Order Request, Defect Management.
Location and Scope
Italy (5 sites), Brazil (1 site), Serbia (1 site) Number of users: 50 up to 100 Types: Plant Operator, Quality Manager, Quality Operator
Support Model
Turnkey packages were delivered by Hyla Soft-Europe. Hyla Soft resources outsourced in Siemens were deeply involved in the development and deployment of the solution (50% of the team).
10
#8 Case #8: FERRARI Functional Scope
MES system development for handling of assembly lines: PLC communication, barcode reader integration, warehouse management integrated with PLC, order and WIP management, label printing.
SIMATIC IT Modules
POM, MM, OEE, PM, PDEFM
SIMATIC IT Libraries
SIMATIC IT Libraries: ILD-LOG, CIL-ERP, CIL-E2S, CIL-PRM, ILD-COM
Language Skills Italian, English
Key Performance Metric Used Conformance to plan, conformance to cost.
Project Management
Internal project team guided by a Siemens Project Manager coordinating with a Hyla Soft Technical Leader. Monthly meetings and conference calls.
Location and Scope
Italy Number of users: 30 Types: Plant Manager, Quality Manager, Quality Operator, Line Operator
Support Model
Hyla Soft (Turin) delivered the work packages using internal resources. Hyla Soft resources outsourced in Siemens were deeply involved in the development and deployment of the solution (33% of the team).
On/Offshore Resource Split Onshore, Hyla Soft (Italy) – 100%
11
#9 Case #9: Coca Cola Hellenic Bottling Company Functional Scope
Covering of secondary processes with integration to customer business systems and line automation. Roll out in 25 factories in Eastern Europe.
Challenges
Development of a single template fitting with a large roll out in different plants and countries. Coordination of activities with SAP, automation and the business team to stay aligned with the strict roll out plan.
SIMATIC IT Functionality
ERP Integration, Order Management, Pallet & Labeling, Secondary Management, Material Management.
Language Skills English
Key Performance Metric Used
Conformance to plan, conformance to cost, adherence to the SAP roll out schedule.
Project Management
Internal project team guided by a Siemens Project Manager coordinating with a Hyla Soft Technical Leader. The work package project team was guided by a Hyla Soft Project Manager. Monthly meetings and conference calls.
Location and Scope
Austria, Bulgaria, Cyprus, Romania, Switzerland, Serbia, Bosnia, Belarus, Ukraine, Russia, Czech Republic. Number of users: 325 Types: Plant Manager, Shift Supervisor, Quality Manager, Quality Operator
Support Model
Turnkey projects delivered from design to installation and delivery by Hyla Soft (Europe).
On/Offshore Resource Split Onshore, Hyla Soft (Europe) – 100%
12
#10 Case #10: Monsanto - Crop Protection Chemicals Functional Scope
To comply with new regulations from ANVISA (Agência Nacional de Vigilância Sanitária- The Brazilian Health Surveillance Agency), Monsanto implemented a new MES solution based on the SIMATIC IT MES Product and stopped using their existing MES system. The previous MES system, totally customized, incurred high maintenance costs and technical changes were nearly impossible to implement. Based on the SIMATIC IT product, Monsanto decided to implement a fully ISA 95-compliant solution. One of the primary targets for Monsanto was to standardize the MES solution in order to roll out the solution in other Monsanto facilities.
Challenges
Short delivery time required to meet new regulatory deadlines with regard to traceability.
SIMATIC IT Functionality
ERP Integration, Production Order Management, Material Management, Genealogy, Secondary Management, Reporting.
Support Model
Hyla Soft (Brazil, Italy), subcontracting to Siemens, provided a project team to coordinate the activity.
On/Offshore Resource Split Onshore, Hyla Soft (Brazil) – 80% Offshore, Hyla Soft (Europe) – 20%
Language Skills
Portuguese, English, Italian
Key Performance Metric Used Conformance to plan, conformance to cost.
Project Management
Project team composed of a Project Manager coordinating with a Project Leader (Senior Business Analyst) and several Software Engineers. Weekly review with Siemens and plant meetings and calls/webinars with the customer.
Location and Scope
Brazil with possible additional roll outs in Brazil, Argentina and USA Types of users: Administrator, Super User, Operator User, Line Analyst
13
3. MANUFACTURING INTELLIGENCE PROJECTS WITH SIMATIC IT Case #11: R.J. Reynolds Tobacco Company (as Siemens Consultants) RJ Reynolds (RJR) Tobacco Company currently has a SIMATIC IT MES solution managing the production for two manufacturing plants: Tobaccoville (TVL) and Operating Companies (OpCo). There are several legacy systems used to manage business and production processes. These systems, as well as Simatic IT, leverage on database technology to store relevant business and production information. Since DBMS and the software versions on which these systems rely are different (SQL Server, Oracle, Excel), the old business and production reports used by RJR management had to query multiple non-homogeneous and disconnected systems spread out across the network. The necessity of moving to a unique platform, along with the desire to fully integrate the data stored in the different data sources, lead RJR to implement a Data Warehousing turnkey solution based on the Siemens Manufacturing Intelligence (MI) product. The project called MQDW (Manufacturing Quality Data Warehousing) started in September 2011 with the purpose of integrating the customer’s data into one centralized Siemens data repository which offers superior reporting performance by means of optimized data structures and denormalization techniques. Siemens Manufacturing Intelligence was the most suitable product as it provided an automatic way to extract, transform, integrate and load data coming from the two Simatic IT plants mentioned above into a centralized data repository. A customized solution was needed by the customer for handling the legacy systems data.
Hyla Soft was part of the team in charge of the following activities: Requirements collection and functional design specification (FDS) Commission of Siemens Manufacturing Intelligence 2.0 Development and commission of 50 production reports Expansion of MI architecture to allow integration with legacy systems Development of the logic to extract, transform, integrate and load data coming from legacy systems into MI data structures Development of OLAP cubes to extract customer’s relevant information
The team was able to successfully collect the customer’s requirements and presented an official FDS document containing technical information about the proposed multi-layer architecture and adopted technology.
14
#12 Case #12: Pirelli Tyre (as System Integrator of Siemens Intelligence Suite) Hyla Soft functionally designed the solution (reports, logic, aggregation protocols, KPI) and analyzed the external systems that needed to be integrated with the Siemens Intelligence Suite. The primary goal was to standardize the reports that generated by all manufacturing plants worldwide (26) and to develop a set of scorecards for middle and top management. The original customer approach for reporting was:
The following benefits are to be accomplished at the completion of the project: Effortless correlation of data Automatic data flow from production databases to manufacturing data marts Data Quality improvement
No availability of detailed manufacturing data
Standard reporting for single and multi-plants
Strong effort and delay in configuring single and multi-plant reporting
No effort in aggregating and correlating data
Not proper decisional support to management by the current reporting tool
Decreased costs to handle plant-specific changes Easier design approach to single-plant custom report Increased analysis capability of manufacturing data
In this specific case, a third party database needs to be integrated with Siemens Intelligence Suite. The acquisition and data loading process from the production data base into a third party database will be realized with ETL (Extract Transform and Load Activity) that will be developed ad hoc in order to guarantee the best results in terms of performances and data cleaning techniques.
15
4. CONSULTING ACTIVITY IN SIEMENS PROJECTS Sab Miller
Sab Miller implemented an Enterprise manufacturing intelligence using SIMATIC IT intelligence Suite. Hyla soft consultants were involved in design, development, test and commissioning of the template and is now involved in the roll out in the SAB Miller European plants. Production phase activities performed:
Coca-Cola Enterprises Functional Scope
Production Execution linking Batch information coming from the shopfloor interface with the Process Order information coming from the ERP system, manage the Process Order status and the Process Order Operations
Order Management; Material Management; ERP Interface; Quality; OEE; Energy Consumption. CCE decided to substitute their SCADA system with an MES system providing main functionality for production, quality and energy control. Production control is aimed to reduce operator misunderstanding providing a sequencing mechanism for order activation: blowing, filling and packing sequence should be always the same system to also avoid multiple orders of the same type on the same line. Production also interfaces with SAP. Quality control is used to pursue a continuum enhancement in quality of the product and to reduce scraps and waste. More than 100 quality forms have been implemented and more than 20 in-line SPC control KPIs have been implemented. Energy control was implemented to reduce unnecessary energy consumption during week-ends and machine downtime.
Acquire and archive Key Operational Parameter links to a Process Order (Production parameters, Quality parameters)
Nestlé Waters North America
Define standard interface to acquire information from the ERP solutions (Material Master, Planned production schedule, Product definition) (Base on the ISA95) Define standard interface to acquire Batch data from the shop floor automation system (Batches data, Procedures data, Steps data, Parameter Values, Material Movements) (Base on the ISA88)
Acquire and archive Key Operational Parameter links to the Equipment (Production parameters) Manage automatic or manual breakdowns and maintenance notification Manage and calculate the Overall Equipment Effectiveness in packaging lines and other strategic KPIs (TEEP, MTBF, MTBR, Speed loss, Quality loss, Performance loss, Micro stoppages) Visualize and analyze Production Parameter Trends comparing different data sources and periods Define a predefined set of brewery oriented KPIs (Extract loss, Yeast grow, Mash liquor: grist ratio, Brewhouse cycle time, Boiling duration) Calculate the predefined Key Performance Indicators at each plant Aggregate KPIs in central data system
Functional Scope
Nestlé Waters North America needed a middleware system installed at all of their bottling facilities to integrate SAP data/ orders/material movement to the manufacturing plants as well as collect and post data back to SAP about the orders in terms of production data, consumption data, material receipts, etc. This system also required a Business Continuity Process (BCP) built in that allowed plants to run when SAP was down and to also reconcile data/orders/material movement with SAP data/orders once SAP was back online. The purpose of the last requirement was to integrate SAP data/orders/material movement to Nestlé’s legacy system SAM. This solution was to be standardized throughout the company and was called Factory Floor Middleware. Hyla Soft implemented this system based on SIMATIC IT at approximately 14 plants in the US.
Visualize KPI scores and specific Reports
16
Kraft Foods (Primary)
Rolls Royce
Order Management, Material Management, ERP Interface, Tank Farm Management, Material Reception (only for coffee plants), Transport Orders (only for chocolate plants), PLC or Microbox Data Concentrator. Kraft identified the need of having an MES capable of receiving orders and materials from SAP, splitting SAP, managing batches, downloading information to Automation, controlling batch execution, registering movements and reporting good receipts back to SAP.
Design and support for the implementation of
Functional Scope
Kraft Foods (Secondary/Packaging) Functional Scope
Order Management, Material Management, ERP Interface, CU, SKU and Pallet Labeling. Kraft identified the need of having a MES capable of receiving orders and materials from SAP, managing data to be printed in the packaging process, managing manual printing and automatic printing exchange information with the Kraft Printing Service, registering pallets created/verified and reporting good receipts back to SAP.
Gerber Baby Food
Functional Scope
the integration layer and logics between Teamcenter and SIMATIC IT MES the MES system for Rolls Royce in the Derby plant and Singapore plant Rolls Royce Specific library based on SIMATIC IT ACM Library
FIAT Group
Functional Scope Design and implementation of a FIAT MES system and roll out in the US Design the MES footprint for Chrysler Project Management activity applied to FIP Plastiche plant to assure Fiat Group the proper project coordination to handle:
>
information integration, project timing, conformity checks to
>
minimization of economic impact of required software development and project risks;
>
achievement of project goals
keep high quality levels of standard product;
Functional Scope
Gerber Baby Food is owned by Nestlé USA and required a middleware system installed at all their bottling facilities to integrate SAP data/orders/material movement to their manufacturing plants as well as collect and post data back to SAP about orders in terms of production data, consumption data, material receipts, etc. This system also required a Business Continuity Process (BCP) built in that allowed plants to run when SAP was down and to also reconcile data/orders/material movement with SAP data/orders once SAP was back online. The purpose of the last requirement was to integrate SAP data/ orders/material movement to Nestlé’s legacy system SAM. This solution was to be standardized throughout the company and was called Factory Floor Middleware and also provide an OEE module that integrating to Factory Floor middleware, SAP, and SAM.
17
CONTACT EUROPE HEADQUARTERS Corso Europa 800-16148 Genoa Italy +39 010.307.0911 +39 010.307.0900
[email protected]
NORTH AMERICA HEADQUARTERS 55 W Monroe St. Ste 2575 Chicago, IL 60603 +1 630.652.0045 +1 630.652.0049
[email protected]
SOUTH AMERICA HEADQUARTERS Av. Queiroz Fliho 1700 Sala 601C São Paulo - SP Brasil +55 (11) 9945.74011 +55 (11) 4302.5976
[email protected]
