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Steel Sap PDF
Steel Sap PDF
White Paper
Industrial Sector
Table of Contents
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Highlights
The steel industry is enjoying strong
growth but is driven by uncertainty
around the value of the dollar,
balancing supply and demand and
rising operating costs. The bottom
line is that todays Steel industry is
changing quickly.
Highlights
CEOs need information systems which
quickly provide them the data they need
ERP can provide that data.
What is ERP?
ERP or Enterprise Resource Planning is IT software that integrates business activities across an enterprisefrom product planning, parts
purchasing, inventory control, and product distribution, to order tracking.
ERP may also include application modules for the finance, accounting
and human resources aspects of a business. SAP and Oracle are the two
ERP leading vendors.
From a business perspective, ERP today has expanded from simply
coordinating manufacturing processes to being the integrator of enterprise-wide backend processes. ERP has also evolved technologically
from a monolithic legacy implementation into a flexible, tiered, clientserver architecture.
ERP Project Risks
In the late 1990s many ERP projects started, but more than a few failed.
While ERP projects remain challenging even today, most can now be
successful because the best practices have been identified and ERP professionals are more knowledgeable and more experienced with making
the projects successful.
Highlights
ERP Business Benefits
ERP is an enabler of business benefits
alone initiative with the requirement to pay back its implementation cost.4 The
spend and savings from improved sourcing policies, (2) decrease of work-in-
being harmonized.
Highlights
ing ERP, as described below. A successful ERP project will start by analyzing
these challenges in detail across all of the companys integrated processes.
This analysis will result in the basic decisions that will be the foundation of the
ERP project.
Challenge 1: More than one planning strategy
Steelmakers often use a combination of production planning strategies. Typically
the flat or strip products are make-to-order, whereas the long products are maketo-stock. Depending on the existence of a de-couple point, finish-to-order could
be a relevant planning strategy as well. Such a combination of planning strategies affects the design of most ERP processes, including supply chain processes
as well as the financial/cost control processes. Cost control in make-to-stock
tends to go for standard price approaches, but in a make-to-order environment
costing happens on an individual order cost collection and forecast basis. ERP
systems today can handle this kind of complexity.
Challenge 2: Complex product variations
A steel product is made up of a large number of characteristics, making the
product difficult to configure when entering it in the ERP system. Configuration in
the make-to-order entries is typically done while entering the order, whereas for
the make-to-stock entries, configuration is done in the product definition, that is,
on the material master.
This burdens the early discussions during the design phase of an ERP implementation. Fundamental decisions need to be made very early in the project
about how many (finished product) materials should be defined: one extreme
is to define by material group which needs to be configured completely in the
order, or the other end of the spectrum is to define all possible/feasible characteristic combinations which can possibly explode into an extremely large number
of finished product definitions.
Finished
CRC
Gauge: .025
HRC
Gauge: .020
Gauge: .015
Gauge: .25
Slab
Gauge: .010
Gauge: .15
Global Business
Services
IBM Business
Consulting
Services
Page 9
Highlights
block (unless inventory already exists that meets the order) and feeds back
IT investments.
a promise date (at the end of the block to allow for the flexibility of possibly
moving to an earlier date).
The mill optimizer then typically would re-shuffle orders in between the blocks,
and feed results back into the SCM application in order to optimize the load
balancing.
Right before production starts, planned orders from the SCM application are
converted into production orders and, via the ERP system, are transferred
into the MES layer. It is at that time when quantities are being translated into
pieces (slabs, coils etc.).
Detailed scheduling then takes place, sequencing and combining pieces
from various orders throughout the mill into lots for optimization.
Production completion then posts an updated status of the orders into the
FIN, HR,..
Level 4&5
Sales Orders
Manufacturing
Inventory
QM
SCM
Demand Planning
ATP
ATP
PP
SNP
SNP
B/W
KPI
Balanced Scorecard
Reporting
Level 3
Inventory Allocation
Slab & Plate Design
MES Melting Shop
Level 1&2
Process
Control
Process Control
Machine Control
Control
Highlights
ERP and MES (process control and machine control) systems, where
the system is actually combination of custom-built applications and
manual spreadsheets. Bridging this gap properly is essential for
realizing the business benefits of the IT investments.
If the applications in Figure 3 are to provide true value, they need
to be robust, integrated and cost efficient. A recent IBM survey
indicates that steel clients process control and MES systems are
custom-built applications 66% of the time, and that these custom-built
applications usually differ from mill to mill.5 Clearly, this risks creating
sub-optimal processes and leaves the company open to all the problems of maintaining custom-built, legacy applications.
Highlights
SOA breaks applications into smaller, granular software components which use
industry-standard methods to communicate and inter-operate.6 SOA moves
away from the one size fits all approach to one that fits more industry specifics
and customer specifics, all on a more productive development environment. SOA
makes it easier to incorporate new and innovative business processes and gives
more deployment flexibility.
A recent steel industry example for SOA is the IBM project in 2005 with a stainless steel company based in Brazil. The SOA architecture provides the company
with real-time views of critical cost and profit information for every key decision.
They now have an integrated solution that can provide real-time cost and profit
information online. This is essential in times of soaring raw material costs, especially for stainless steel manufacturers where Nickel and Chrome costs need to
be analyzed separately.
The steel company designed and implement the new ERP system based on core
mySAP modules (which are pre-SOA architecture), plus several SOA-compliant
software components. The ERP modules are integrated with the clients asset
management, production planning and packaging systems. The Integration
Message Broker, which is part of IBMs Websphere software, allows important
transactional data such as materials consumption and purchase orders to be
freely exchanged from the Oracle database to all of the companys systems.
This platform has proven to become the glue providing management online realtime cost and margin information which is needed for robust decisions in the
volatile stainless steel market.
Conclusion
ERP is a key backbone application for companies in a fast changing industry
like steel. Given an awareness of the best practices and a good understanding
of the project complexities, the risks in an ERP implementation are usually outweighed by the benefits. The ERP discussion is often one of mindset more than
one of standalone business cases.
While implementing ERP can be challenging and demands sustained commitment from top executive levels, it is fundamental to enhancing the competitive
position of a company in the dynamic environment of the steel industry today.
References
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BCW01695-USEN-00