Improve Project Delivery with Superior Document Control SAP PLM and bdf PCC for Electrical Engineering in Heavy Industries

Transcription

1 Improve Project Delivery with Superior Document Control SAP PLM and bdf PCC for Electrical Engineering in Heavy Industries Heavy Industry Summit, Walldorf, 17 th April 2012 Ulrich Martel (SMS), Dr. Ralf Huber (bdf) 1

2 Approach of bdf Process Control Center (PCC) based on SAP PLM Engineering Process Requirements Design Engineering Production Delivery Usage Top Down Definition PCC for Orchestration & Control of Engineering Processes PCC approach combines Process Orchestration & Control Top Down Definition of individual customer requirements SAP Business Suite Classic BOM PLM Function & Features Variant Configuration CAD Interface Engineering BOM Master Data Classic BOM Projects Archiving Change Order Document Structures Purchase Order Production Order Bottom Up Selection Bottom-up selection of SAP PLM Function & Features Value Add by matching SAP PLM features to Engineering Processes 2

3 What is bdf PCC? Modification Free Add-On to SAP Standard* Flexible, dynamic structure** Processes Tendering Projects Documents Material Supplier Integration Project Mgmt Engineering Delivery Process optimized user interfaces SAP GUI Web Client HTML5*** Features Variant Configuration, Hierarchy, History, Baselining, Costing, Archiving, Integration SAP Business Suite - Key Business Objects PO, SD, BOM, PSM, MD, C-Projects, PS, 3 * From 4.6C EhP6 ** based on SAP Product Structure Management ***currently Protoyping

4 SMS Siemag, the united know-how of many companies Worldwide some 10,600 employees generated a turnover of EUR 3 billion

5 Global Presence SMS Siemag EA Hilden Düsseldorf Germany Mülheim Hilchenbach USA Pittsburgh, PA China Beijing India Delhi, Kolkata 5

6 Complete metallurgical process know-how from steel making to finished products 6

7 Successful commissioning 2009 to 2011 Steelmaking plants Continuous casters Hot rolling mills Cold rolling mills 10 Steelmaking plants (incl. 29 EAF, CONARC, BOF, LF, AOD units) 6 SAF (Submerged Arc Furnace) plants 32 Individual items (EAF, CONARC, BOF, LF, AOD/VD) 4 Revamps (EAF, LF, SAF) 3 CSP casters with 6 strands 11 Slab casters with 14 strands 10 Revamps with 30 strands (CSP, Slab, Bloom, Billet) 3 CSP mills 2 Conventional hot strip mills 5 Heavy-plate and Steckel mills 8 Sections in heavy-plate mills 4 Revamps (conventional) 4 Cold rolling mills (RCM, TCM, SPM) 2 Revamps (cold rolling mills, aluminum) Strip processing lines 5 Strip processing lines (PL,CAL,CGL,ETL, ) 7

8 References Steel Making Plants and Single Units North American Stainless (EAF, AOD) ServerCorr (EAF, Twin LF) Griffin Wheel (EAF,LF) Arcelor Packaging (BOF) CST (LD, BOF) Celsa (EAF, LF) Profilarbed (EAF) ACB (EAF) Rico Echeviria (LF) Maghreb Steel (EAF,LF) Peiner Träger GmbH (EAF, 2LF) Corus Staal (LF) Celsa (EAF, LF) ALZ (EAF) Georgsmarienhütte GmbH (2 LF) Aubert & Duval (EAF, LF) Trinecke Zelezarny A.S. (2 BOF) Eko Stahl GmbH (2 BOF) Isdemir A.S. (3 BOF, LF) ZAO Forpost Management (EAF) Halyvourgia (EAF) OAO KEMZ (EAF, LF) Tagangrog (EAF) Kaptan Demir (EAF) Hormozgan Steel Complex (2EAF, 2 LF) Acciai Speciali Terni (AOD) Ural Steel (EAF, EAF, Twin LF) JSC Pervouralsky Novotrubny (EAF, LF, VD) Seversky Tube Works (EAF, LF) Essar Steel (2 Conarc, 2 Twin LF, LF) IISCO Steel Plant (3 BOF, 2 LF) Tata Steel (2 BOF (Kalinganagar), 3 BOF (Jamshedpur), 2 BOF (Kalinganagar)) Jindal South West (2 BOF, 4 LF) Pervouralsky Novotrubny Works (EAF, LF, VD) Neelachal Ispat Nigam Ltd. (BOF, BOF) Baotou (LF) Tianjin (EAF, LF) JISCO (EAF,LF, AOD, VOD) Alloy Steel Plant Ltd. (AOD) Visa Steel Limited (EAF, LF) Jindal Stainless (2 EAF, LF, AOD) Rotem Company (AOD) Changwong (AOD) POSCO (EAF, LF, AOD) Dragon Steel (3 BOF) Baosteel (EAF, AOD) Feng Hsin (EAF) Bhushan Steel Ltd. (Conarc, 2x Twin, RH Top, 2 BOF, LF) Jindal Power & Steel (EAF, LF) Visakhapatnam Steel (2 BOF, 2LF) Fuxin Special Steel (EAF, LF, AOD) References since 2000 One Hand Supply Technological Supply Electrical Steelplants 19 (16 EAF, 3 CONARC, 22 LF, 7 AOD/VOD) + Converter Steelplants 10 (23 BOF, 10 LF) + Single Units 57 (18 EAF, 2 CONARC, 13 BOF, 5 AOD/VOD, 19 LF) 8

9 Scope of Supply Drive Control Field Components PLC Systems Power Supply Automation Layout

10 All drawings should fit with the standardized PLC and HMI software design Common HMI for all levels of Automation Uniform structure

11 What do we expected from an Engineering system to fulfill these requirements? We expect from a Engineering tool is: highest flexibility best quality of our drawings shortest possible project time

12 Processes for Hardware Engineering SAP SAP-PCC EEC EPLAN Electric P8 PSP-Structure (mechanic) Basicdata Projects Rules M&C Project Plant Area Product Netplan Basic Engineering The Engineering process starting with the M&Clist in SAP-PCC, data transfer to EEC for generating EPLAN projects and Delta- Engineering in EPLAN Projects Rules Functions Toolboxes Technical Databank Drawings Parts-lists Signallists Detail Engineering 12

13 Engineering Workflow in HW-Engineering 3 Steps to the Solution Step 1: Application Engineering Updating of Master Data, Typical and Eplan Macro Basic Engineering a) Generating of Motors- and Components List b) Generating of Automation Configuration c) Danger-Zones, E-Stop Circles, Control Circles Detail Engineering a) EEC Generating of EPLAN Electric P8 Projects b) Delta Engineering with EPLAN Electric P8

14 Step 1: Updating of Master Data for SAP-PCC / EPLAN Z-Kat-Teil Standard office SAP-Mat.-Nr. Manufacturer Type Shapes div. Atrributes EAP 5 Standardisation Typicals, electrical Variations Mechanic construction Elektric construction SAP-PCC EEC EPLAN Electric P8 1:n relation between Typical and Material Application Engineering from SAP Material No. until definition of electrical conditions for EEC and EPLAN P8

15 Engineering Workflow HW-Engineering 3 Steps to the Solution Application Engineering Updating of Master Data, Typical and Eplan Macro Step 2: Basic Engineering a) Generating of Motors- and Components List b) Generating of Automation Configuration c) Danger-Zones, E-Stop Circles, Control Circles Detail Engineering a) EEC Generating of EPLAN Electric P8 Projects b) Delta Engineering with EPLAN Electric P8

16 Step 2: Basic Engineering, Providing of Input Information SAP PCC Generating of Motors- and Components List Definition of Plant Configuration Definition of M&C-List and Link to Mechanical PSP-Structure Definition Field Equipment with Automation and Signal List Definition of Automation Configuration e.g. Profibus Assign Field Equipment to CPU Signal Information for Software Export EEC Definition of Danger Zones and Control Circles Definition depending on Safety Concept and Risk Analysis

17 Step 2: Screen Shot Product Designer Workbench

18 Engineering Workflow in HW-Engineering 3 Steps to the Solution Application Engineering Updating of Master Data, Typical and Eplan Macro Basic Engineering a) Generating of Motors- and Components List b) Generating of Automation Configuration c) Danger-Zones, E-Stop Circles, Control Circles Step 3: Detail Engineering a) EEC Generating of EPLAN Electric P8 Projects b) Delta Engineering with EPLAN Electric P8

19 Step 3: EPLAN Engineer Center (EEC) Library: Toolbox Parts Rules and Parameters Variations SAP- PCC Generating EPLAN Project: EEC is the Control Center between SAP-PCC and EPLAN in order to generate circuit diagramms, HW-Configuration and Signal Lists Takeover of data out of SAP PCC Calculation of Parameters Decision of Variants Generating of EPLAN Documents Connecting Link and Control Center for the HW

20 Step 3: EPLAN Electric P8, Automatic output and Delta-Engineering Circuit Diagrams HW Arrangement Drawings Generation EPLAN Terminal Lists Cable Lists Part Lists Output Documents of EPLAN: 1.Arrangement drawings for cubicles and desks 2.Current diagrams 3.Cable lists 4.Terminal lists 5.Part lists

21 Facts on bdf and PCC bdf focus is on high performance applications for PLM and Finance for SAP customers bdf strategic approach to offer add-on s to SAP Business Suite to close gaps & deliver round offs approx. 70 employees, whereof 25 developers PCC is a modification free Add-On to multiple SAP releases 26 live customers Discrete Industries, DACH & EMEA SAP certified solution English and German version Full service offering including development support and maintenance 21

22 Use-Cases PCC-DCC Engineering Supply Chain - Documents Example Process: 1. Easy-DMS Create Document 2. Stamping, Transmittal & Distribution 3. Receive Document Package 4. Response 5. Reporting 22

23 PCC-DCC Solution: Collaborative Document Control DCC Solution Map Document Structure Document Planning Document Control Document Acquisition Print & Archiving Desktop Integration cfolders Integration Methodology & Implementation Folder Structures Engineering Object Scheduling Purchase Planning for Documents PDF Generation Easy DM Integration User Creation MDDL Concept Project Management Virtual Document Process Control BANF creation Template Maintenance Packing table Collaboration Separate IMG Doc Type Hierarchy MDDL Scheduling Strategies Document Order Stamp Maintenance Excel Integration Folders ASAP Methodology Visible Node Virtual Classification Progress Tracking Incoming Documents Change Notification Easy DM Archiving Documents Best Practices Delivery Noden Document Generation Automated Confirmation Acknowledgement & Status Management Production Order Web Client Status Network MDDL Content Structure Upload Numbering Generation Document Distribution Message Control Recycle Bin PS -Integration Planning Strategies Distribution Codes Certification DCC Copy Mass Up-& Download User Creation 23

24 Contact Dr.-Ing. Ralf Huber: 24