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At one of the largest manufacturers of specialty chemicals, specifically those used in the Oil and Gas sector, all the process recipes used to manufacture their products, were managed using a legacy mainframe computer. Being a legacy system, it had no support and posed a big risk to the business. The legacy system which held the recipes, was not integrated with SAP, which was used to generated process orders based on those recipes, making it very had to keep the two systems in sync.

The execution was paper based. The operator instructions were printed from the legacy system. This led to the operation to be inefficient, lacked traceability, and had challenges with compliance.

The Solution

The project was executed in two phases.

In Phase 1, all recipes across all manufacturing processes and product families were reviewed, standardized, and digitized, using global standard operations and phase templates, and master recipes were created in SAP PP-PI.

In Phase 2, the xMES Engine was implemented which enabled executing the recipes on a handheld device, thus completely eliminating paper-based execution. Also, as a part of phase-2, an OEE dashboard was designed and deployed, leveraging SAP MII.

Value delivered
  • Enabled complete digital transformation of Recipe Management
  • Conversion of all recipes to SAP PP PI Master recipes
  • Developed standard and global templates across all plants
  • Re-usability and standardization of processes
  • Easy to use graphical Recipe Management Tool
  • Enabled complete Paperless Execution using Electronic Work Instructions
  • Auto generated Electronic Batch Records
  • Complete Traceability of products
  • Enforced compliance
  • Integration with Safety & Training systems
  • Integration with SAP & PLC/SCADA