Domino Sugarstreamlines

production recording using MII

Mike Olson
Director Enterprise Architecture
American Sugar Refining, Inc.
Company Overview
Only sugar supplier with national brands
Distribution channels include
Ingredients, Food Service and Grocery
customers
Produces more than 1500 SKUs of both
branded and private label products
First Sugar Cane Company to produce
certified organic sugar
Produces a full line of rice products,
including half of all the rice consumed in
South Florida
Consumer Goods
Florida Crystals Corporation and the Sugar Cane Growers Cooperative have created the first fully integrated
sugar cane company in North America, taking products fromfield to shelf. The addition of the Domino , C&H ,
and Redpath brands has created a North American distribution capability.
Farms 245,000 acres in South
Florida
Operates 2500 pieces of farm
equipment
Crop is harvested between
October and April
Uses rice for crop rotation
Operates three sugar mills and a
rice mill
Mills process >1MM tons of raw
sugar annually
Farming
Operates refineries in New York,
Baltimore, South Florida, New
Orleans, San Francisco,
Toronto, and Mexico
Operates a 130 Megawatt
cogeneration plant
Produces more than 3,000,000
tons of refined sugar annually
Refini ng

Strategy
The strategy of growth through acquisition has consistently increased the
operating complexity and the need for innovative solutions that support the
business requirements.
1995 1998
FCC selects and
implements SAP
Begins vertical
integration
strategy
consumer
products
FCC and SCG
acquire J ack
Frost (RSI)
American Sugar
Refining (ASR) is
acquired by RSI
Domino Foods sales
and marketing
cooperative is launched
with its own SAP
system
Agile and adaptive
systems infrastructure is
adopted and developed
Assets are optimized
across the combined
enterprise
All SAP systems are
upgraded to the same
version
C&H acquired
establishing national
footprint
American Sweetener
Corp acquired from
Chr Hansen
2001 2005
Sugar Stix acquisition
enhances tabletop
product line & capacity
Acquisition of Ingenio
San Nicolas provides
capacity and
distribution capabilities
in Mexico
Optimization of
production &
distribution assets &
related business
processes are planned
in conjunction with a
continuous
improvement
initiattive.
RedpathSugar is
acquired by ASR
providing North
American footprint
Acquisition did not
come with any
technology
applications
Required to get off
of Sellers
technology within 90
days
Leveraging
technology carve-
out from past
acquisition
C
o
m
p
le
x
it
y

2006 2008
Project Overview
We need better reporting for packaging performance,
especially in terms of how we did compared to the plan
Sr. VP of Operations
Current Process
This was our existing Scheduling Process
Current Process
This was our existing Reporting Process
Manually Key Results into Custom SQL DB via .Net ASP Pages
Export Data to Excel One Plant per Workbook, one Sheet per Day
4MB+Exported File Per Plant
Pain Points Two Related Requirements
Improve Packaging Efficiency Reporting
The current system has the following weaknesses:
1) No way to see plan verses actual performance
2) Accuracy of actual running time verses downtime
3) Limited reporting and anal ysis capabilities in the excel
process
Improve Metrics Reporting:
Additionally, there is a need to improve the metrics reporting process.
1) Create a central repository for metrics data
2) Capture the data as close to the source as possible (at
least dail y)
3) Automate the calculations and reporting for
presentation
Packaging Efficiency Requirements
Accounting
Purchasing
People Change
Management
Time to
Implement
Other
Considerations
System Requirements
Put the schedule into SAP - SKUs by line
by shift with QTY to produce Need for
Pack Efficiencies and Digital Packaging
Record production with start and end
time, packaging downtime, non-
packaging downtime and reason codes.
Scrap in the near future with digital
packaging.
Replace existing schedul e Process with
SAP
Replace existing packagi ng efficiency
reports
Generate new Reports / Analytical Tools
Dont break the cost/plant profitability
reporting
New Process: Schedule via SAP PP and Confirmw MII
Single source of master data (line names,
product names, work center hirearchy)
Eliminate duplicate entry of production
Schedule visible to everyone, all the time
Simplified schedule view and entry
through MII
Baseline to compare planned vs. actual
New BI reporting with OEE, select time
range, etc.
Ad Hoc Analytical capabilities through new
Business Objects Webintelligence
Future integration with weekly, monthly
and long term planning
SystemRequirements
Put the schedule into SAP - SKUs by line by shift with
QTY to produce Need for Pack Efficiencies and Digital
Packaging
Record production with start and end time, packaging
downtime, non-packaging downtime and reason codes.
Scrap in the near future with digital packaging.
Replace existing schedule Process with SAP
Replace existing packaging efficiency reports
Generate new Reports / Analytical Tools
Dont break the cost/plant profitability reporting
Project Overview
Switched from repetitive to discrete manufacturing to:
Eliminate off line scheduling process
Leverage more standard functionality for performance reporting
Facilitate shift reporting in the future (EHP3)
Prepare for Sales & Operations Planning in 2010
Partnered with Acsis, Inc.
Needed to simplify recording process
Quick project turnaround needed
Completed in approximately 8 weeks
Implementation Approach
Utilize MII:
Simplify production recording vs. CO11n
Provide ability to record shift and validate against SAP shift
config
Custom BAPIs to extract schedule and hierarchy data so
displayed in useful format for the operators and to support BW
reporting requirements
Data posted using standard order confirmation BAPI
Use SAP Business Objects for Reporting
BW Extractions Hourly based on Standard Cubes
BW and Business Objects Web Intelligence Reporting
New Process Scheduling Step 1
Create production order
TCode: COO1
New Process Scheduling Step 2
Dispatch ProductionOrders TCode: CM25
New Process Step 3: Communicate the Schedule
New Process Step 4: Packaging and Reporting Results
Demonstration of MII Production Schedule and Recording
New Packaging Efficiency Reporting fromSAP BI
Benefits
Single View of the Schedule
Accountability for tracking All Time (8 hrs per shift)
Reduced Data Entry on the Packaging Side
Overall Equipment Effectiveness Metrics (OEE)
Conformance to Plan
Overage Tracking
Next Steps
Roll out to additional refineries locations
Integrate with automated manufacturing lines
Integrate additional shop floor systems to SAP
Questions?