AGENDA

Introduction to TietoEnator, and MES components

Project Background & Objective
Project Organization
Project Scope
Project Methodology
Project Schedule
Process Flow for PPM-1,2,3 and Functionality
TIPS Screen
MOPS Screen
Key Performance Index (KPI)
 INTRODUCTION TO TIETOENATOR
TietoEnator Forest Division

⚫ 700 people dedicated to Forest Industry Solutions

⚫ Over 30 years' experience
⚫ Over 250 Systems installed in Paper Mills around the
world
⚫ Offices in Scandinavia, Germany, USA, Canada and
Singapore
⚫ Opening in Indonesia in 2004
⚫ Expanding in China in 2004/2005
 TE’s MES COMPONENTS
TIPS
TIPS Web ERP Systems
Sales

TIPS IC

TIPS TIPS TIPS

Mill Order Plan Trim
Handling

TIPS TIPS
Base Mill TIPS DW
Lab

TIPS
Store

TIPS IPC TIPS WebReport TIPS Collect

PLC, Quality measurement, Automation

 PROJECT OBJECTIVES
Real time visibility of Mill operations by Sales
and Marketing
Access to unit level inventory data
On-line access to production schedules
On-line access to order status and production status
On-line access to pallet and roll quality data for claim
handling
Integration of Mill operations with Sales and
Marketing
On-line confirmation of ATP
On-line reservation of inventory
Automatic allocation of inventory and production for
order fulfillment
 PROJECT OBJECTIVES
Improved management of internal Mill processes
On-line WIP
Production tracking
Improved quality control and visibility
Production schedule flexibility
Computerized trim optimization
On-line material requirement planning and
management
Access to timely and accurate information for decision
support
Consistent reporting of operational data across
enterprise
Common production and inventory reports
Common KPI benchmarking, definition and reporting
Common coding and naming systems
 PROJECT OBJECTIVES
Integration of mill operations with SAP enterprise
system
Real-time inventory updates
Material consumption and requirement planning
Integrated order processing
Integrated shipment planning and document generation
Improved planning and operational performance
Capacity utilization
Waste minimization
Reduced downgrade
Reduced production over/under run
Improved Delivery In Full On Time
Improved inventory accuracy and age management
 MES ORGANIZATION STRUCTURE
STEERING COMMITTEE
Mr.Teguh Ganda Wijaya / Eric Oei, Michael Black, Terry Hunley,
Anton Mailoa, Buyung Wahab / Eero Palokangas,
Hendra Kosasih, Lin Shun Keng, Tsai Huan Chi, Mark Collins
PROJECT ADVISOR
Lu Kuang Lieh
PROJECT MANAGEMENT TEAM
Ming Santoso, Putera Jaman, Radjasjah Koesoema,
Thomas Nusanto, Nigel Saville, David Pawelke, Bob Fearn

IK-PRW CORE TEAM PINDO DELI CORE TEAM CHINA MILLS CORE TEAM Corporate IT CORE TEAM
Team Lead & Coordinator : Team Lead & Coordinator: Team Lead & Coordinator:
Radjasjah K. & Ngardy N., Thomas Nusanto, Budiman Team Lead & Coordinator:
Gan HuaFeng,
David Pawelke, Bob Fearn Salim, Lukas Leonardo, Gideon Halim S.,
Yu LiZhong (GHS),
David Pawelke, Bob Fearn
Members (Paper Product) : Members (Paper Product) : Members (Paper Product) : Members :
Jhony Tanoto (S&M), Eko Widiyatmoko (S&M), Lu Yu (GHS), Christian Kosasih,
Hendra Bahar (PPIC), Suranto (PPIC), Wei Jiansuo, Jimmy Chandra,
Jasa Guanwan (Ppr.Machine), Agus Darmansyah (P.Mach.), Xue Jing, Arman Sukiri, Ferdinan,
Tahir Taman (F/N & C/V) Taufik Kilruddin (F/N & C/V) Yang Bo, Rudy H.Sulistyo,
Thayer Alwi (QAD), Hartono Jonathan (QAD), Robinson C., Yulianto,
Liu Feiyu
Sucito Hung (F/G W/H), Agus Djatmiko (F/G W/H), Yudi P.Jaya, Limijati,
Sunarto Sun (Ship.Plan), Hrman Hemanto (Ship.Plan),
Ling Jianfeng, Eric.L.Sutanto
Subari Wiratno (Transport), Syahrin Pardomoan(Transp.),
Zulfiandri (Mach.Eng), Shen Jiangyong, Benny Alex., D.Suryadi,
RK Rao (Mach.Eng.),
Sufinocoyo (Mill-IT), Zhou Tao. Yudie P., Liqi Wijanto
Multazam Masturidi (Mill-IT),
Eric Lang (TE). Eric Lang (TE).
IK-Prw MES Functional team
IK-Prw MES Executive Support team
 PROJECT SCOPE – System Functionality
M E S - S A P In te g ra tio n S AP T e r r ito r y T ie to E n a to r 3 r d P a r ty

F o re c a sti n g B u d g e ts C o n tra c ts L o g i sti c s O p ti m i z a ti o n (A P O ) F i n a n c i a l P l a n n i n g

Enterprise
Functions

D i stri b u ti o n
S RM CRM T ra n sp o rta ti o n ATP , CTP , P TP E -C o m m e rc e
P la n n in g

S h ip m e n t
O rd e r E n try P ri c i n g & T e rm s C re d i t G l o b a l I n v e n to ry D e l i v e ry O rd e rs
P la n n in g

E q u i p m e n t D a ta D o w n ti m e
P u rc h a si n g M a te ri a l s I n v e n to ry M a te ri a l s Q u a l i ty M a i n te n a n c e
M a na ge m e nt S ch e d u lin g

M a ch in e M a te ri a l
C ycle P la n n in g M a rk e t A l l o c a ti o n T ri m O p ti m i z a ti o n B i l l s o f M a te ri a l s
S ch e d u lin g R e q u i re m e n ts
Mill Level Functions

P ro d u c ti o n
G ra d e R u n S p e c 's P a p e r M a kin g Q u a l i ty W I P + F G F i n i sh i n g C o n v e rti n g
S ta ti sti c s

G ra d e R u n D o w n ti m e M ill U n it L e ve l W h s U n it L e ve l
M a c h i n e I n te rfa c e s P ro c e ss I n te rfa c e s
H i sto ri e s R e p o rti n g I n v e n to ri e s I n v e n to ri e s

C o n ta i n e r
D e ta i l e d S h i p m e n t C o n ta i n e r
O p ti m i z a ti o n L o a d P la n n in g L o a d i n g & S ta g i n g C o sti n g
D o c u m e n ta ti o n M a na ge m e nt
(C u b e I Q )

M i l l w i d e I n fo rm a ti o n S y ste m (M O P S )

E x p o rt D o c 's S h ip p in g S h i p m e n t T ra c k i n g In vo icin g M i sc D R 's a n d C R 's N o n -P ro d u c t S a l e s

Enterprise
Functions

P ro fi ta b i l i ty
S a l e s A n a l y si s C la im s R e ce iva b le s P a ya b le s P a y ro l l
A n a l y si s

P e rso n n e l F i x e d A sse ts G e n e ra l L e d g e r T re a su ry D a ta W a re h o u se B u si n e ss A n a l y ti c s
 PROJECT SCOPE – APP
Products
Fine Paper – Cut Size, Folio, Rolls
✓ Wood-free / Photocopy
✓ Carbonless
✓ Cast Coat
Tissue
✓ Rolls
✓ Converting
• Market Pulp
 PROJECT SCOPE – PRW Mill
Products Systems
Fine Paper TIPS and MOPS
✓ Cut Size, Folio, Rolls
✓ Wood-free / Photocopy
✓ Cast Coat
Tissue TIPS and MOPS
✓ Rolls

• Market Pulp TIPS and MOPS

Scope of IK-Prw Machine Interface

PPM1
✓ Link to Measurex QCS for Production Quality Data and Profile
✓ Link to Honeywell DCS Through QCS Link
✓ Link to New RCS Roll Handling System , Kraft Wrapper

PPM2
✓ Link to New QCS
✓ Link to Yokogawa DCS (Still Option in new QCS Scope)

PPM3
✓ Link to Measurex QCS
✓ Link to New Upgrade Honeywell DCS
✓ Link to Roibox Web Inspection System
✓ Link to Lab Autoline System
✓ Replace Lamb Roll Handling System Computer System by TIPS

Cast Coat
✓ Link to New Sicma Roll Handling System , Kraft Wrapper
Scope of IK-Prw Machine Interface

Finishing 1 and 3
✓ No Interface Link to Machine Control System
✓ Plan to put PC Workstations with Bar Code Scanner on each
Cutter/Wrapper.

Converting 1 and 3
✓ No Interface Link to Machine Control System
✓ Plan to put PC Workstations with Bar Code Scanner on each
Cutter/Wrapper.

Finished Goods Warehouse

✓ Pallet ID and Bar Coding Implementation
 PROJECT METHODOLOGY

Usage
Planning
• Current Business Process

Live Operations
Analysis

Performance Test
Project Initiation

Operational Test
• Business Process Reengineering Software Development

Acceptance
• Identify Software Tools Usage Software Releases

Go Live
Training
• (SAP,TIPs,MOPS) Interface Testing
• Define Software Functionality Project Communication
Requirements
• Define Gaps
• Document Detailed MES
Solutions
• Project Communication
• Finalize Project Schedule
• Usage Planning Report
• Report Acceptance
PROJECT SCHEDULE
 IK-Prw first phase start-up

Scope of Plan & Trim / MOPS Start-Ups

TIPS Plan and Trim MOPS
• SAP Order/Order Change Interface • DCS/QCS OPC Interface
• Capacity Planning Forecast • Process and Production
• Block Schedule – Analysis
– Paper Machines – Reporting
– Coaters • MOPS Historian
– Sheeters • WIN MOPS User Interface
• Trim Optimization
– Sheeter through Winder
• Winder Production Instructions
APP USAGE PLANNING SCHEDULE
 PPM 1 dan 2 Process Flow
FG/R

ROLL
FGRolls WRAP
RCS
FG/R
WR01M
PAD1 Slitter
F. Victor ROLL
To WRAP
PAD2 SICMA
RW01M
SFG/R FG/S
WR02M
2x 3x 2x 3x 2x
Ream
Cast PALLET
PM1 Winder Winder Sorting Wrap&
Coaster WRAP
Palletize
Folio
PM01M WI01M SFG/R CC01M WI04M 7x RM01M WP01M
4x LOADING
ST01M Hand Hand
Folio Polar CS Pack& PALLET
Palletize WRAP

2x FS01M GL01M BM01M WM01M

SFG/R

FG/S
PM2 Winder SFG/S
Duplex
Sheeter
PM02M WI02M
SFG/R DU01M Sorting

To SFG/R
PAD2 ST02M
CS1-1M RM1-1M WC1-1M
CS1-2M RM1-2M WC1-2M
CS1-3M RM1-3M WC1-3M
From
CS1-xM RB1-xM WC1-xM
PAD2
 PPM 3 Process Flow
FG/R
From
PAD1

ROLL
PAD2 FGRolls
WRAP

FG/S WR03M

SFG/R 4x 2x
Ream
PALLET
Wrap&
To WRAP
Palletize
PAD1 4xSimplex
Folio RM03M WP03M
Folio Sorting 4x
2x
Hand Hand
FS03M Polar CS Pack& PALLET
PM3 Winder SFG
From Palletize WRAP LOADING
PAD1 ST03M
WI03M GL03M BM03M WM03M
PMO3M
ASRS
SFG/S FG/S
Sorting

ST04M
SFG/R
CS3-4M RB3-4M WC3-4M
CS3-5M RB3-5M WC3-5M
CS3-6M RB3-6M WC3-6M
CS3-7M RB3-7M WC3-7M
CS3-8M RB3-8M WC3-8M
CS3-9M RB3-9M WC3-9M
CS3-10M RB3-10M WC3-10M
From
CS3-xM RB3-xM WC3-xM
PAD1
 TIPS Screen: Graphical Production Planning

Consecutive
Machines Cycle
Planned
Details

Production Cycles
•Colour coded
•Green = trims
•Grey = orders
•Red = some late orders
•etc
Screen: Reel Production
 Reel Functionality
The paper machine functions are used to register and assign a quality classification to the reels produced in the
Description mill, i.e. to cover the production tracking from the paper machine to the winder.
Tracking begins at the paper machine where the produced machine reels are registered to the run currently
active in the paper machine. The heritage of the reels is registered and the produced length waste. The reel
tracking covers the following basic functions:
1.Reel registration at the paper machine
2.Acknowledgement & quality classification of reel
3.Changing the reel data manually
4.Event logging & viewing reel-info
Every reel is automatically registered on the paper machine by using the information coming from the
DCS/QCS (i.e. Measurex) When this message is received, the reel is automatically registered in the system.
Optionally the reel can be added manually if connection to a DCS is not available. The user checks, corrects
and completes the received data and acknowledge the reel. The reel can be assigned to the final winder
pattern(s) to optimize the reel sizes.
When the reel is acknowledged a bar-coded reel tag can be printed.
When the reel data has been verified, the user has to accept the reel quality. The system will be set to forbid
further processing of the reel before the reel has been classified. This can be done when the reel data is
accepted or with a separate function i.e. in the laboratory. The user can also add free text comments, e.g.
quality information.
Input •Production run (grade/orders) from Planning
•Quality Specification from basic data
•Quality data from DCS
•Quality data from lab systems
Output •A classified jumbo reel, with quality data, for processing at the next station
Screen: Quality Map from Lab & QCS

Graphical view of the measurements from QCS systems

 Screen: Quality Diary

Tabular and graphical view of the properties of produced reels

Trim – Solution
Screen: Winder
 Winder Functionality

Description The winder's function is to convert jumbo reels into smaller width and/or diameter rolls as
required by the customer or stock order. This is accomplished by slitting the reel in the
correct positions to achieve the desired width.
All patterns planned by production planning are available for cutting at the winder.
Winder operators can perform functions such as changing positions of orders or adding
butt rolls or stock rolls.
Before a set can be reported finished, a jumbo reel must be mounted at the winder. This is
done by identifying the jumbo reel with the reel number.
Input •Trim Patterns from Planning
•Jumbo reels from production, with an assigned quality specification
Output •Correctly registered and classified rolls, ready for further processing.
•Non prime product with correctly assigned reason codes and textual notes
Screen: Folio Sheeter
 Folio Sheeter Functionality

Description Sheet orders are assigned to the production plan cycle of the machines defined in the machine
chain.
Parent roll (for conversion to sheet orders) availability is ensured either from available rolls in
the inventory, and/or an internal roll production orders.
The roll orders are trimmed and the roll production runs are created and at the same time the
sheet production runs are created.
Rolls are produced and appear in the SFG (semi finished goods) inventory for sheeting.
Sheeter runs (actually the orders/patterns in the sheeter run) can be checked by the planning
department and assigned and scheduled to a specific sheeter during the fine planning process.
This results in a sheeter machine specific cutting program. At the same time the physical
availability of the rolls can be ensured.
Skids (pallets of semi-finished sheeted goods) are produced and can be further processed and/or
wrapped as finished goods inventory.
Input •Trim Patterns from Planning
•Fine planned processes from Planning
Output •Correctly registered and classified skids, ready for further processing.
•Non prime product with correctly assigned reason codes and textual notes
Screen: Cut-size Sheeter
 Cut-Size Sheeter Functionality

Description The Cutsize process provides the ability to order, plan, schedule, and produce cutsize product.
This capability is integrated with order processing and manufacturing functions to ensure the
efficient production of customer orders.
When managing cutsize orders, there are 3 main areas of focus:
1.Order entry
During order entry, it is important that the customer service representative be able to quickly
and easily quantify the product (and all its attributes) being ordered. To this end, the cutsize
process will rely heavily on the specification of a bill of materials (BOM)
1.Scheduling
During rough planning and fine planning, it is important that the user be able to collate cutsize
orders of “like production” together. “Like production” includes similar finishing materials,
sheet sizes, and manufacturing grades. Users must have the ability to define these aggregation
attributes themselves, and then assign production patterns accordingly.
1.Production
The production of cutsize sheet product is heavily driven by finishing material requirements.
In addition, it is important to provide as much traceability between the palletized product and
the machine backstand rolls as possible to ensure the paper is of sufficient quality for the
customer.
Input •Trim Patterns from Planning
•Fine planned processes from Planning
Output •Correctly registered and classified pallets, ready for further processing.
•Non prime product with correctly assigned reason codes and textual notes
 Screen: Product Heritage Tracking
Jumbo Reel to Roll

Jumbo Reel to Roll To Folio

to Ream Wrap
Warehouse Map

Loading Activity

Picking Activity

Shuttle Activity

Warehouse Bays

Graphical view of the activity in the warehouse

 Mill Layout

Graphical view of all Production units and intermediate storage inventory

Screen: MOPS
Mill Overview
 Key Performance Indicators
Reporting Areas KPI’s

Finishing & 1. Reduce Production Paper Waste

Converting 2. Reduce Broke
HBD 3. Increase Capacity Utilization
M/C 4. Increase Production Plan efficiency
PDD 5. Reduce Trim Loss - Winder , Sheeter
PPIC 6. Improve paper quality (timely paper quality information)
7. Improve pulp quality (timely quality information) Mach 8,9,10
PPM
8. On-time availability of packaging materials
QAD 9. Aged Inventory
Raw Materials 10. Reduce Idle WIP
Sales & Marketing 11. Container Detention per month
VTEAM 12. Reduce the number of quality checkpoints
Warehouse 13. Reduce Production Overrun
14. Inventory Synchronization (TIPS/SAP)
15. Inventory Control Supply Level (< 10 days Domestic <40 days
export)
16. Accurate Inventory Level (FG,SFG)
17. Answer inquiry and create quotation in 5 minutes
18. Convert inquiry into and order in the system (< 10 sec)
19. Respond to claims/complaints in 2 days
20. Provide flexible and accurate Supply Chain Planning (98.5%)
21. Claim reduction