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Information Delivery at Dow Corning: Key to Innovation and Delivering Operational Excellence
The silicone technology pioneer A joint venture of Corning, Inc. and The Dow Chemical Company Organized to explore the potential of the silicon atom in 1943 Dr. Franklin J. Hyde Page 3
Dow Corning innovating around the world More than 7,000 products and related services Approximately 25,000 customers $3.88 billion in sales in 2005, globally dispersed with more than 60% outside the US 9,000 employees worldwide Global leader in silicones and high purity silicon metal Strong channels to market distributors, web, commercial organization Page 4
We serve customers diverse needs Automotive Beauty & Personal Care Chemical Manufacturing Construction Electronics Food & Beverage Healthcare Household & Cleaning Imaging Paints and Inks Power and Utility Solar Pressure Sensitive Rubber Fabrication Textile, Leather & Nonwovens Page 5
Dow Corning locations worldwide Manufacturing Sites Page 6
Dow Corning s SAP Landscape 1996 deployed a single global instance Landscape Today ERP 2004 (ECC 5.0) XI 3.0 (NetWeaver 2004) BW 3.5 (upgrading to 7.0) EP 6.0 / EP 7.0 EBP 4.0 (Run on NetWeaver 620) CRM 5.0 (NetWeaver 2004s) SCM 4.10 GTS 300_640 (NetWeaver 640) Solution Manager 5.0 (NetWeaver 2004s) xmii v11.0/11.5 Page 7
Key Challenges across Mfg and Supply Network Productivity Improvements key to maintain margins Response time to customer inquiries were unacceptable Poor visibility into manufacturing exceptions across the enterprise and the supply chain Poor decision support multiple data sources for right time decision making Tool for every platform and vendor Inability to sustain Six Sigma improvements Struggled communicating the business strategy at every level of the organization and maintaining alignment Page 8
Strategic and Tactical Goals Drive Supply Chain productivity and Operational Excellence Delivering the corporate priorities strategic improvement goals Meeting Customer needs EXACTLY improved response time Differentiated Supplier of Silicon Materials Aggregate data from multiple sources across enterprise Improve quality thru automation of Six Sigma processes and lower quality expenses Enhance employee accountability through actionable intelligence Lower TCO with common platform Page 9
Information Delivery Pipeline Page 10
Enterprise Manufacturing Data Analysis System: A global solution for manufacturing decision support Integrates process, business and quality information through out the supply chain. Individual supply chains can Support process optimization Pursue aggressive variability reduction goals response rapidly to customers Page 11
Advanced Technologies and Ventures Business 2003 Pilot Project Scope Opportunity Statement Balanced AMB rapid and effective scorecard methodology will ensure implementation of it s business strategy Making tradeoff decisions Facilitate organizational alignment to achieve business goals Identify Six Sigma improvement opportunities Drive improved performance and provide measurable target, strategic goals and accountability Page 12
Information Delivery Strategy - A Common Information Delivery Framework That facilitates delivery of information: subsequent steps of the user s workflow Data to Insight to Action That empowers Businesses and functions to create information & performance views on their own From sources throughout the enterprise (vs. vendor centric) Drill down, drill across, analytics, and alerting Web based Page 13
Enterprise Manufacturing Data Analysis System: Approach using SAP Information Delivery Architecture Standardized Access Tool Browser (Internal and External Audience) Available Content based on your Role Delivery & Integration Framework Delivery Workbench Content iview Dynpro/.Net Web Apps Drag & Relate Content Content iview SAP Portal Content SAP xmii Content iview Eventing Content iview BI/BW Web Dely Content Roles & Users Active Directory Data Sources SAP CRM Data Whse Mfg Data BW Documentum (etc.) CRM Information PI, LIMS R/3 Information Sources - Internal and External Siebel, IIS, GDW, etc. Page 14
One Case Study: HSC SAP xmii Analytics Pilot Supply Chain Visibility Provided a step change in our ability to monitor and improve work and manufacturing processes and secondly, improve stability, root cause analysis and provide a step change improvements in quality and cost reduction New upstream visibility & early detection Root cause analysis tool Action taken without impacting end product quality or customers Historical analytics Page 15
Performance Mgt: Site Level & SC Performance Analytics Deliver KPI s and supplement analysis Driving productivity measures across in the Supply Chain PLAN, SOURCE, MAKE, DELIVER <RETURN> - with standard solutions that are extensible and help solve very specific issues particular sites have. Abstraction layer for backend integration, maintains consistent, highly functional user interfaces across multiple sites. Page 16
Performance Mgt: Business and Industry Focus Every employee understands how their work impacts the strategic improvement goals of their business through score carding with detailed drill down capability. Within a single view, clearly quantify the businesses performance across a wide range of KPI with real-time analytics tied directly into disparate backend systems. Page 17
Performance Mgt: Enables Corporate EIS Delivering key performance indicators (KPI s) and historical views which measure corporate performance across our four corporate priorities Provides our executive team a common framework and delivery mechanism for the entire corporation with detailed business cuts into the performance. Page 18
Delivering Analytics: Business Process and Product Quality in-process analytics that are tightly integrated into our business processes; drawing from multiple data sources and providing drill-downs designed to facilitate the user s workflows. Automatically aggregate data from multiple backend systems. Page 19
Composite Analytics: Condition Based Maintenance Plant floor and ERP Integration - Significant saving on PM cost through plant floor integration and improved asset management. Users are able to create their own maintenance monitors based on set methods closing the loop with the shop floor. Page 20
Sustainable Control Plans : Integrated Plant Floor Analytics Plant floor and ERP Integration - Provides a conduit for cross process analytics and tighter plant floor integration and synchronization with ERP for Sustainable Six Sigma results. Provides Visibility across multiple systems Real-time status coding Alerting & voice messaging Historical analytics Page 21
Results Summary Increased employee productivity millions of dollars in savings Reduced customer response time from days to 1-2 hrs Drive Business Strategy align and drive performance Sustainable Six Sigma processes lowers costs and improved quality Support Increased sales higher customer satisfaction Realized lower total cost of ownership single instance of SAP ERP, SCM, Visibility and Interoperability Page 22
Next Steps: Traction to Acceleration - Deliver Our Vision - Common Analytics Framework - Continued SOA Deployment - Adaptive Business Models - Portal Integration - Mfg xapps Analytics - Drive Automation - Operational Intelligence -Customer Value Page 23
Lessons Learned Faster, better informed, decision making The right information at the right time Drive Out NVA Freedom to Innovate Leverage common framework and reusable components extensible across the enterprise Streamlining global workflows by providing in process analytics powered by service oriented architecture Empowering the Business matching the skills, meeting the needs leveraging the expertise of the troops on the ground Not about a tool, its about capitalizing on opportunities going fast, taking risks, and learning Page 24
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