PSImetals towards Globalization, PSImetals UserGroup ... · • Delivered on a “ready-to-use” CD (including documentation) … which can be later extended to a “full-featured”

© PSI Metals 2011Slide 1

Luc Van Nerom

PSImetals towards Globalization, Scalability and Rollouts

for:

PSImetals UserGroup, Salzgitter, 27-28th September 2011


PSI MetalsUrbi et orbi


Global solution provider for the metals industryCustomer and market expectations

High quality product

Scalable solution

User friendly

Customizable

Standard releasable product

Integration is easy

Performance

Agility, adapt to changes

Flexible supplier-customer partnership

Cost saving

…


PSI Metals global solution supplier point of viewProduct Design• Standardization• Know-how packaging• Support local customization• Integration

Product Architecture• Common Framework• Modular and scalable architecture• Embedded integration

Business Approach• Solution supplier• Customer partnership• Rollout strategy• Release management• Project management


Product Design: PSImetals 5


Product Design: GlocalisationLocal language and units


Product Design: know how packaging example Standard KPI’s

CT = Cycle Time[h]

T = Tons[t]

TPH = Tons Per Hour[t/h]

TR = Transaction Rate[%]

U = Utilization[h]

UR = Utilization Rate[%]

Y = Yield[%]

Y1A = Yield1A or Quality Rate[%]

OEE = Overall Equipment Efficiency[%]

I = Inventory[t]


Product design: know how modelingexample Steel Quality Data Model

Remark:STANDARD extension is used for special treatment (as heat treatment)GRADE extension for special analysis conditions

Chemical Analysis (ordered in steel plant)S024

C 0.16 – 0.184, Mn 1.45 – 1.6 etc….

External Quality (customer order)10160 01 51410

EN10025-2:2004 S355J2

Standardextension

Gradeextension

SteelStandard10160

EN10025-2

Revision01

( Year 2004)

SteelGrade 51410S355J2

Internal Quality


Product design: configurabilityexample Rule Editor


Product design: compatible international standardsexample PSIintegration -- Standard Adapters

PSIintegration provides a set of standard interface solutions that can be used directly out of the box

• Call an SAP service via XI or receive an XI call from SAP• SAP IDoc: Send, receive • SAP-BAPI/function: Call, receive• Read/write database tables with name based field/column mapping• Read/write JMS queues• Read/write IBM MQSeries queues• Read/write TCQueues• Send/receive via TCP/IP (leading length formats)• Call/provide WebServices (SOAP)• File access


WS server(receiver)

Product design:SOAP based SAP integration

SAP

SAP PI Integration Engine

SOAP adapter(sender)

TCQ

SOAP adapter(receiver)

WS client(sender)

GenerateMessage

ProcessMessage

Verify Message

PS

Imeta

lsP

SIi

nte

gra

tio

nS

AP

PI

> 7

.0 S

P1

3

IDOC AdapterRFC Adapter

Proxy

IDOC AdapterRFC Adapter

Proxy

TCQ TCQ

ProcessMessage

Outbound Inbound


Product Architecture: toward one frameworkPSI Java Framework

PJF (PSI Java framework) components in PSI Metals

• PSIgui Gui framework• PSIluf Look and feel for GUI• PSIwsm Work space manager and windows controller• PSIlog Logging• PSIi18n Internationalization• PSIexc Exception handling• PSIprop Property handling• PSIvisu 2D visualization• PSIpos Output service• PSIiface Interface handling


Product Architecture: PSImetals 5 migrated to PSIgui


Product Architecture: Coming soon from PJF

New component PSIlicCode protectionPSIgui• New features for grid

- Grouping- Sum and other math function

PSIvisu• Integration in PSIgui • Functions like

PSIauth• Kerboros – single sign-on• GUI upgrade to PSIgui 2.5

PSIdds• Data distribution service• Out of database

Multi-touchable screen functionality


Product Architecture: PSImetals 5Software component modularization


Product Architecture: Integration point of view

Oracle RDBMS

PSImetalsGUI Components

JAVA

JDBC

Third Party SystemsL2-L4

SAP Portal

PSImetalsPlanning Clients

ODBC

GUI Integration Services

Application Components

PSImetals Framework Components

PSIintegration

Application Integration Services

Home - Index - PSImetals: Runtime Architecture

Planning PersistenceLayer

Order Dressing


Product Architecture: PSIintegration

Architecture, infrastructure and process model for the implementation of message/telegram interfaces between applications

Developed as the standard framework for building interfaces between PSImetals and its partner systems

Often used to solve common Enterprise Application Integration (EAI) or middleware tasks

PSImetals

ERP1 P1 SAP

A B C D E

SourceSystem

TargetSystem

SourceAdapter

TargetAdapter

TCQueueTelegramBrowser


Product Architecture: embedded integrationPlanning Persistence Layer

PPL is a highly configurable persistence layer between the Factory Model and the planning and scheduling components. It maps the Factory Model to the object model of the planning & scheduling components.

Planning Persistence LayerOrder Scheduling

MasterPlanning

Caster / Line Scheduling

Plate/CoilCombination


Scalability example 1A plate mill plant in the USA (Dixie)

Production & Material PlanningScheduling

Production Execution & Material Logistic

Demand & Sales Planning

Commercial Processes

PS

Imeta

ls

Sales OrderEntry Pricing Costing Billing

Production Order

Life Cycle

Material &Stock

Management

ScheduleExecution

Management

ProductionTracking

Quality Control& DeviationManagement

Warehouse &Transport

ManagementDelivery

Caster &Meltshop

Scheduling

Hot MillScheduling

Cold Mill &Finishing

Scheduling

Order Dressing

Production Configuration

SalesOrder

Dressing

ProductionOrder

Elaboration

DemandForecasting

SalesPlan

Optimisation

Due DateQuoting

InventoryOptimisation

Plate & CoilCombination

InteractiveMaterial

Allocation

MasterPlanning

Capacity PlanManagement

CampaignOptimisation Order Scheduling

PurchasingPlant

Maintenance…


Scalability example 2HSM scheduling in the USA (Great Lakes)





PS

Imeta

ls


Production Order

Life Cycle

Material &Stock

Management

ScheduleExecution

Management

ProductionTracking



ManagementDelivery

Caster &Meltshop

Scheduling

Hot MillScheduling


Scheduling

Order Dressing


SalesOrder

Dressing

ProductionOrder

Elaboration

DemandForecasting

SalesPlan

Optimisation

Due DateQuoting



InteractiveMaterial

Allocation

MasterPlanning



PurchasingPlant

Maintenance…


Scalability example 3 Production Execution in Belgium (Wallonia)





PS

Imeta

ls


Production Order

Life Cycle

Material &Stock

Management

ScheduleExecution

Management

ProductionTracking



ManagementDelivery

Caster &Meltshop

Scheduling

Hot MillScheduling


Scheduling

Order Dressing


SalesOrder

Dressing

ProductionOrder

Elaboration

DemandForecasting

SalesPlan

Optimisation

Due DateQuoting



InteractiveMaterial

Allocation

MasterPlanning



PurchasingPlant

Maintenance…


Scalability and Modularity gives Flexibility

Start with PSImetals Logistics “Base Package”

Favourable Logistic solution• basic solution for small and common projects• mostly customizable• Delivered on a “ready-to-use” CD (including documentation)

… which can be later extended to a “full-featured” solution• adding Yards

by configuration• adding Featurs

by upgrades

Base Package

Plug&Play Software

Additional Functionality

Additional Training &

Config.Customized Software

Basic Training Ready to use


Business Approach:A global solution provider around PSImetals 5

From Project Driven to Standard License, Consulting & Maintenance Driven

Releasable and upgradeable product

From System Integrator toPartner of IT-departments of our Customers

Deliver applications and consultancy to experienced implementation partners

Develop rollout strategies with multi plant customers


Business Approach:Product Based Roadmap

Q2 2011

5.1 5.25.3 5.4

Q4 2011

Q2 2012

Q42012


Business approach:Project & Market Driven Release Plan

5.2Q2 2011

5.4Q2 2012

5.5Q4 2012

5.3Q1 2011


Business approach:Develop rollout strategies

Starting point: existing IT-landscape of the customer

Define and implement PSImetals kernel system for one production process

Add functional extensions (horizontal extension)

Extend kernel system to other production processes (vertical extension)

Define and develop customer specific PSImetals solution framework

Rollout PSImetals solution to other production sites

PSImetals


Business approach:Map customer IT-landscape to the PSImetals solution

Planning

Quality

Production

Logistics

Base Automation Mapping

ERP mapping

Functional Mapping

MM SDPP

MES Hot end Warehouse Slab & Coils

SlabyardMeltshop/Casters CoilyardHSM

L2 CC L2 HSM


Business approach:Vertical Extension to the cold end

MM SDPP

MES Hot end Warehouse Slab & Coils

SlabyardMeltshop/Casters CoilyardHSM

L2 CC L2 HSM

Cold Finishing Coilyard

MES Cold end

L2 Cold End


Business approach:One Customer - Different plants

Avilés, SpainBurns Harbor, USLiège, BelgiumTubarão Espirito, Bra.Dofasco, CanadaDunkerque, FranceEisenhüttenstadt, GGalati, RomaniaBremen, GermanyHochfeld, GermanyRuhrort, GermanyFos-sur-mer, FranceDunkerque, FranceFlorange, FranceAvilés, SpainGijón, SpainACB, SpainBurns Harbor, USAVega do Sul, Brazil

Thyssen Krupp

TK SteelTK RasselsteinTK Electrical SteelTK StainlessTK VDM

TK Electrical Steel- Bochum, Germany- Gelsenkirchen, G- Ugo, France

TK Nirosta- Benrath, Germany- Krefeld, Germany- Dillenburg, G.- Shanghai, China- Mobile, US

Borlänge, SwedenMobile, USKunshan, ChinaOxelösund, Sweden

Aulnoye, FranceDüsseldorf, GermanyYoungstown, USVSB, Brazil

Beautor, BelgiumClabecq, BelgiumFarrell, USLa Louvière, Belgium


Business approach:Develop a customized solution architecture

Sol

utio

n PS

Isui

tePS

Imet

als

Kosice … Mobile Kunshan …Lake Erie


Business approach: Multi site copy & paste rollout

Planning

Quality

Production

TDW

Planning

Quality

Production

TDW

Planning

Quality

Production

TDW

Planning

Quality

Production

TDW

MM SDPP


PSImetals in ThyssenKrupp Electrical Steel

© PSI Metals 2011Slide 33 Thys

senK

rupp

Source: Fit im St@hl: Effizientes Projektmanagement im heißen IT-Projekt, 08.06.2005, Dr. Wolfgang Trommer, Günter Sube

A Company of ThyssenKrupp

Steel

33

ThyssenKrupp Electrical Steel EBG

Starting Point: IT- Landscape

Controls

MMPM PPQM SDCO FI

pickling cold rolling annealing coating slitting adjusting packaging

Beize

EBZ LVS H 31-36MB2

MB1UWA1UWA2

EBRPR -KWR

PLSD-Öfen

ISA1ISA3 LZ1 LZ3 LZ5LZ7BZE BZA KWR1KWR3 KWN DO4 DO5 DO6

Betriebsdatenerfassung

IBISPlantafel Materialfortschreibung / BestandsverwaltungFertigungsauftragszuordnungAggregat-

kapazitäten

BS2000

Trans08

Medea U

Adlatus

QuasiAdonis 1

Adonis 3PARIS - Rückmeldeverarbeitung

APOLLO41

Zeus / Änderungsdienst

HGLLVS

H10,12

BDE-Korrektur-

system

Rückmelde-verarbeitung

APOLLO6

SAP

ShopFloor

packaging

package (Fert)Cold rolled Coil (Halb)Prematerial (Roh)

Businesslogic

VestaTages-bericht

VS


BZ KWR1 KWR3 EBR DO4 DO5 DO6 HGL ISA1 ISA3 LZ4 EBZLZ5 LZ7

Landcscape in Gelsenkirchen after Implementation of PSImetals

Planning

Quality

Production

TDW

MMPM PPQM SDCO FI

Businesslogic


Planning

Quality

Production

TDW

Planning

Quality

Production

TDW

Planning

Quality

Production

TDW

Planning

Quality

Production

TDW

TK Steel Europe ES Shopfloor –Final vision

Bochum Gelsenkirchen Isbergues Motta Visconti

MMDP PP/DS PPQM SDCO FI

Businesslogic


Business Approach:Project management – a new dimensionProject management becomes

much more demanding:

Big project volume

Projects are strategic for customer

Implementation of PSImetals in several plants

International teams in different locations

Team size needs sub-projects and a formalised communication


PSI Metals

Stepping into a Bright Future!

Thanks for your attention

Documents

PSImetals towards Globalization, PSImetals UserGroup ... · • Delivered on a “ready-to-use” CD (including documentation) … which can be later extended to a “full-featured”