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producer of carrageenan extracts in the world
As a leading specialty chemical company, FMC Corporation seeks to enhance people’s lives in multiple ways, advancing the manufacture of hundreds of essential products. Needing standardization and real-time information sharing to keep up with fast paced business, FMC turned to SAP solutions to integrate global manufacturing and business systems.
Philadelphia, Pennsylvania, USA
Tata Consultancy Services Ltd.
SAP Manufacturing Integration and Intelligence rapid-deployment solution for batch manufacturing, SAP Enterprise Resource Planning
A leader in agricultural, specialty, and industrial chemical markets, FMC employs advanced technologies for research, mining, and manufacturing to produce customized products and solutions. FMC’s customer-focused research and development provides innovative, cost-effective solutions for industries from food and agriculture, to pharmaceutical, healthcare, and manufacturing.
FMC’s vision is to become a larger, stronger, and more global company with a corporate culture of innovation, integrity, responsibility, and customer intimacy. In key consumer and industrial categories, FMC is actively investing in growing organically, expanding in rapidly developing economies, and centralizing ownership and systems.
Within their manufacturing facilities, FMC had implemented a range of manufacturing execution systems (MES) and distributed control systems (DCS) which were not integrated. With duplicate data entered in isolated systems, reporting was time consuming and data quality was a concern.
FMC has had a long-standing relationship with SAP, using SAP software to power their business systems for years. In developing an infrastructure to meet increasing demand and ensure products are readily available to global customers, FMC decided to deploy new SAP solutions to improve agility, flexibility, and operating efficiency by linking real-time shop-floor updates with key business planners and decision makers.
Inspired by SAP’s “perfect plant” concept, which integrates manufacturing and business systems, FMC began a consolidation project at their facility in Haugesund, Norway. FMC partnered with Tata Consultancy Services Ltd. (TCS), who offered the experience and expertise FMC sought. TCS and OSIsoft PI system personnel rolled out a template-based manufacturing-floor connectivity solution built around the SAP Manufacturing Integration and Intelligence (SAP MII) rapid-deployment solution for batch manufacturing.
SAP MII is a strong integration platform for the SAP ERP application. Role-based dashboards enable FMC employees to gain the insights they need from manufacturing output and from quality key performance indicators to process temperatures, material viscosities, and more. If an operator on the plant floor updates information about a process, that information is immediately available to others elsewhere in the Haugesund facility.
TCS has also integrated SAP MII into FMC’s Microsoft Active Directory system. Should FMC in Haugesund ever need to audit a process, Active Directory audit trails enable system administrators to see exactly who did what and when.
The week we went live, the number of material documents created in our SAP ERP application system for Haugesund rose by 400%. This demonstrated that the data being captured was more concise, giving a real-time picture of how the plant was operating.
The Haugesund facility now operates with a very lean team. Where information used to be days – or even weeks – old, SAP MII lets process engineers and business decision makers pull up reports about the manufacturing environment that reflect real-time data – from a single data repository – for better planning and process execution.
Now well positioned to meet future challenges, batch-manufacturing templates from SAP provide FMC with a blueprint they can use for deploying similar upgrades in other manufacturing plants around the world.
As FMC integrates more of their manufacturing-plant floors with broader corporate business systems, they can build on the infrastructure to operate more efficiently and with greater agility and responsiveness. They can become the larger global entity that they envision – while becoming more capable of meeting the local needs of their clients throughout the world.