Extend the Value of ERP

Integration with manufacturing operations promises substantial benefits.

By Fred Reever, CISUG, and Frank Kochendoerfer, SAP

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30.  With the customer able to allow a three-day delay, the production planner reruns the production plan. The results indicate that Reactor C can be shut down for up to 28 hours with no further product delays. Eight hours is required for the catalyst feed pump replacement and cleaning of the feed system, during which time routine impeller maintenance also can be completed. The planner questions whether the shutdown should be extended to do a complete impeller replacement.
31.  The planner pings the maintenance manager with the question.
32.  The maintenance manager pulls up the maintenance records for the impeller on Reactor C and finds that the impeller isn’t due for replacement for five months.
33.  He responds to both the production planner and control-room operator that he recommends proceeding with only routine maintenance during the outage.
34.  He also responds that he has contacted his maintenance team, alerting them to the pending shutdown and repair. They have responded that they can be in position for the repair in four hours with all parts and labor available.
35.  The production planner reruns the production plan and schedules the shutdown to begin at the conclusion of the current batch in Reactor C, estimated in seven hours. This reduces production rate losses and shortens the two identified customer delays by 12 hours.
36.  The modified production schedule is automatically sent to the control-room operator and the maintenance manager.
37.  Appropriate maintenance orders, production orders, etc. are also automatically updated and issued.
38.  Notification is automatically sent to the sales representative, who notifies and confirms the change with the customer.

Fred Reever, recently retired from DuPont, is a Delray Beach, Fla.-based member of CISUG. Frank Kochendoerfer is director of the chemicals industry business unit for SAP Labs Inc., Newtown Square, Pa. E-mail them at FreevAceed@aol.com and frank.kochendoerfer@sap.com.

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