Transcript BDIS / LIMS

BASF IT Services B.V.
Integration of process control into the supply chain
Use of OSI products
June 2001/ Page 1
CompanyPresentation.ppt
BASF IT Services B.V.
Overview
 BASF group
 BASF IT Services
 SCM for BASF: EURIS LOMAS
 LOGICA for BASF Antwerp
 Requirements and difficulties
 Solution
 Project approach and figures
 Advantages / Disadvantages
 Conclusion
Walter Greubel
12-Mar-2002/ Page 2
BIS_OSI_UC.ppt
BASF IT Services B.V.
BASF is a transnational chemical company
Production offices
Sales offices
Walter Greubel
12-Mar-2002/ Page 3
BIS_OSI_UC.ppt
BASF IT Services B.V.
BASF products are everywhere
Communication
Health sector
Sport &
Leisure
BASF…
a wide
variety of
products
Traffic
Housing
Food
supply
Walter Greubel
12-Mar-2002/ Page 4
BIS_OSI_UC.ppt
BASF IT Services B.V.
Figures
Data in million Euro
1999
2000
Variance
in %
29.473
35.946
+22,0 %
Income from operations
2.009
3.070
+52,8 %
Profit before taxes
2.606
2.827
+8,5 %
Net income after taxes
1.237
1.240
+0,2 %
Number of employees
104.628
103.273
-1,3 %
Sales
Walter Greubel
12-Mar-2002/ Page 5
BIS_OSI_UC.ppt
BASF IT Services B.V.
BASF IT Services
 Creation of BASF PAN European IT Organisation 02-Apr-2001


BASF IT Services B.V.
Headquarters in Waedenswil, Switzerland
 Integration of European BASF IT Organisations of




BASF AG, BASF Schwarzheide, Elastogran
BASF Computer Services subsidiaries
BMS Spain
BIS Italy
 About 2000 employees
 Preferred IT service provider to BASF Group companies in Europe
 Turnover > € 400M
Walter Greubel
12-Mar-2002/ Page 6
BIS_OSI_UC.ppt
BASF IT Services B.V.
SCM for BASF in Europe: Euris/Lomas
 EURIS
European Information and Communication system for marketing and
sales
 LOMAS
Logistic management system
 Impact on production sites, logistic services sales and marketing
bureaus
 Fluent, uniform, transparent and actual information is necessary in
the process from customer order to delivery of goods
 Information actual, uniform and transparent at disposal for sales,
marketing, logistics, distribution and production, at group level
 Dealing efficient with the process ‘customer orders’ – ‘customer
receives’
 …standardize this processes on SAP R/3
Walter Greubel
12-Mar-2002/ Page 7
BIS_OSI_UC.ppt
BASF IT Services B.V.
LOGICA for BASF Antwerp
 Production site of 55 production plants
 Transferring SAP R/2 processes into SAP R/3 and implementation of
PP/PI
 500 users involved
 PP/PI issues:



BBS
1
‘VERBUND’ or production cluster
Mixed : batch and continuous
Complexity: all possible problems are available
EO
Ruw
2
Ethy2
leen
BBT
3
1
1
EO
EB
EB
2
Walter Greubel
3
Gly11
12
10
MEG
colen
3
1
2
EO
EO 4
8
7 MEOA MEOA
EDA
REIN 6 EOA
destil.
CTA
CTA
BBT
5
1
9
Voor
Hoofd
Krist./
2
3
4
reactie
reactie
filtratie
PolySty4
styreen
5
styreen
6
reen
EDA
3
CTA
14
PHD
Panda
Totalplant batch
MM
Manueel/berekend
Meting
Poly15
flasher 5
ether
4
13
7
12-Mar-2002/ Page 8
BIS_OSI_UC.ppt
BASF IT Services B.V.
Requirements and difficulties
 Requirement
collect, reconcile and book automatically all production, consumption and
stock data of the 55 production plants on the site daily
 Difficulties






Before, this stocktaking was done manually
Stocktaking was done on a monthly basis.
Complete stocktaking with reconciliation took 3 days
different timestamps of the collected data
Different registration systems of the collected data
Integrated product flows.
Walter Greubel
12-Mar-2002/ Page 9
BIS_OSI_UC.ppt
BASF IT Services B.V.
Solution
 Integration of process control and SCM:








Grouping of production plants in 6 product clusters
Synchronise the time of closing
Use of commercial available software and existing platforms
Collecting all data on 1 platform: PI
Synchronise the time of closing
Interactive and graphical reconciliation tool as control: sigmafine
Automated booking of orders with PSRlink
Development of an application for steering the dataflows
 Result



All data is collected from 06:00 to 08:00
Reconciliation takes about 30 to 60 minutes per cluster
Booking in SAP is done automatically
Walter Greubel
12-Mar-2002/ Page 10
BIS_OSI_UC.ppt
BASF IT Services B.V.
OSI software packages
SAP PPPI
Rlink
PI
Sigmafine
Customizing
PI-PHD COM Connector
PHD
Panda
Custom development
DCS
Walter Greubel
12-Mar-2002/ Page 11
BIS_OSI_UC.ppt
BASF IT Services B.V.
Project approach and figures
 Approach




Small testcase as feasibility study
All work done in house with some consultancy support
1 FTE for change management
Each product clusters has 1 cluster responsable

Inventarisation of master data is time consuming
 Figures



Timeframe: 1 year
800 mandays
Core team of 5 people
 Advantage



A feasible project
Relatively small project budget
All work done by a small project team
Walter Greubel
12-Mar-2002/ Page 12
BIS_OSI_UC.ppt
BASF IT Services B.V.
Disadvantages
 Structural issues




Overkill: there is still unused potential
Technical part is more easy than the organisational part
The learning is still ongoing especially on the Sigmafine part
Some extra configuration needed in PPPI



Continuous plants modelled as batch plant
resource/ / resource network configuration
System is extremely vulnerable on consistency of data through all layers
 Technical issues



Rlink on sqlserver is very ‘resource consuming’
PHD COM connector is pulling down PHD: tuning is important
Unintegrated configuration
Walter Greubel
12-Mar-2002/ Page 13
BIS_OSI_UC.ppt
BASF IT Services B.V.
Conclusions
 Integration of shop-floor and SCM is important
 Implementation is possible in a ‘running’ company
 Organisational part is more difficult than the technical part
 OSI software makes the project technicaly feasible
Walter Greubel
12-Mar-2002/ Page 14
BIS_OSI_UC.ppt