Hatch was engaged to design a manufacturing execution system (MES) that includes functionality to manage the data exchange between SAP and the melt shop, one
rod mill and two bar mills with level 2 layer
systems.

The main drivers of the project included:

• An SAP system upgrade from series 3.x to the latest version
• Upload of production information in real time to SAP, shortening the information cycle.
  

The MES components included:

• A database engine based on Microsoft SQL Server 2005
  
• A data exchange layer based on SAP PI interface
  
• End-user applications developed in a Microsoft .NET environment with rich and intuitive user interface
  
• A data exchange layer with legacy Level 2 applications (VMS/Fortran).

Scope of Services

Hatch’s Systems & Process Control Group provided the following services:

• Consultation services for project inception and project management
  
• Design of the MES database and application models
  
• Programming and administration of the database
  
• Programming of the current Level 2 applications (VMS/Fortran) to exchange data with the MES level (Level 3)
  
• Engineering services and support for system commissioning.

Project Highlights

• Hatch was involved in a joint team with the client, managing client, Hatch and third-party resources
  
• Key system outcomes:
  
  • Increase management visibility in plant operations while helping operators to perform their job with respect to the plant’s operating procedures
    
  • Products produced on schedule, meeting quality and quantity requirements
    
  • Condition-based maintenance was enabled, allowing better use of the plant’s assets.