Steelman SEMS EBS Addon for Mills

Steel Enterprise Management Systems®
SEMS(tm)

Steelman™ Software Solutions Inc.
Metal Software That Changes With Your Business

© Copyright 2010 Steelman Software Solutions Inc. All rights reserved. Confidential and Proprietary

Steel Specific “Knowledgeware”

• Our strength comes from a proven
understanding of the steel business gained
from hands on experience
– Successful system implementations
– Extensive steel industry consulting history
– Steel management and sales experience
– Experience at:
• Mills
• Processors
• Service Centers
• Fabricators


About Steelman

• VSZ a.s. - fully integrated steel mill 3.6mt
• CSC Ltd. - speciality bar mill 1mt
• Parkdale International – service center
• Midland Steel – tool steel service center
• Pacesetter Steel Services – 5 service centers
• Wheeling Pittsburg Steel Corporation – fully integrated
steel mill
• Steel Warehouse Company – 12 service centers
• Olympic Steel – 15 service centers incl. fabrication


Steelman Product History
BUILT on ORACLE DATABASE & APPLICATION SERVERS
Launched 1996
Steel Mill Melt Shop

Hot Rolling Mills MF
Cold Rolling Mills Launched 2003

Service Centers

Outside Processors SEMS
Assembly Fabricators


International Capable
Example SEMS Handles
• Require separate SEMS company
– Company currency in Paso
– Company document in Spanish
– Unique taxation issues
– Can translate all screens in Spanish
• Changes in Accounting procedures
– Inventory valuation does not include taxes
– Exchange rate is changed daily
– Mexican invoice need amounts spelled out in Spanish
• Duty and customs documents (NAFTA)
• Ownership change only happens when goods cross the
border

Current Locations and Teams

• Head Office • Large core team of steel
– 4850 Keele St. First Floor application and project experts
Toronto, • Steelman comprises a team of
Ontario M3J 3K1 Canada over 50 people
– Telephone 416.495.6939
• Through our offshore partner
• USA Project Office offices we can scale to any
– Cleveland, Ohio, United project size with experienced
States staff
• Reseller Offices
– Kosice, Slovak Republic
– Mumbai, India
– Monterey, Mexico
– Shenzhen, China


THE STEELMAN APPROACH

• The knowledge gained, and the approach and
methodology have been developed by working on the
shop floor with the experts – i.e. the Operators - in
defining the parameters, rules-of-thumb and general
heuristics that have to be incorporated into the solution
to realistically provide tools that lead to change in both
operating practice and procedures


Examples of Previous Successful Projects Utilizing the
Approach and Methodology That Now Form the Nucleus
of the STEELMAN Solution Include;

• Republic Engineered • USS/KOBE Steel
Steels, 1990 -1992; Company, 1991- 1994;
Development and Development and
implementation of: implementation of a
– A Production Planning tool Production Scheduling
(Heat Build Module) which
was utilized to group all tool.
orders into “Buckets” of • AHMSA Mexico, 1995 –
strings of heats. 1998; Provided consulting
– A Production Scheduling and management
Tool for the Melt Shop and
Cast Roll Facility. assistance to the
– A Grade Salvage Tool, steelmaking division to
which would determine the study and improve their
“best” alternative for logistical practices and
processing an off-grade
heat. systems.


Examples of Previous Successful Projects Utilizing the
Approach and Methodology That Now Form the Nucleus
of the STEELMAN Solution Include;

• VSZ a.s. Kosice, Slovakia, 1995 – 1999;
Development and implementation of the
Enterprise wide STEELMAN Steelmaking
Software System for Flat Products, for the
3.6 million tonne/year steel producer.
• CSC Ltd, 1999- 2001, Development and
implementation of the Enterprise wide
STEELMAN Steelmaking Software System
for Long Products, for the 1 million ton/year
steel producer.


Solution Objectives

• Streamline business flows
• Superior customer service
– Capability to promise
– Available to promise
• Improve productivity
• Improve quality
• Reduce cost and working capital
• Informed decisions
• Move to an open and homogenous technology
environment

Order To Cash
Connect Customer, Manager and Plant
Customer Management

Business
Strategy
Actual / and Rules Actual
Planned Demand Predicted
Supply Chain Performance
Availability to Promise Planning
Capability to Promise Scheduling &
Production
Execution Material & Schedules
Resource
Status

Customer Service
Production Plant
Shop Floor

Sales Cash Financial Suite General
HR AP Payroll
/AR MGT Ledger

Dynamic CUST

Commercial Order Routing &
Reject
Entry Provisioning
Management
New Repeat Order Status
Inquiry
C Order Order
OK--
Management

U Claims Product
Promise
Date Accept
Override
Accept
S Quality Design
OPEN
T
O Referrals
Shipping &
M Gate Exiting Scrap Defects Cost
E
R Distribution Product Production
Manufacturing
Routing Recording
Management Control
Carrier In Inventory
Checked
Material Schedule
Assigned Created

Web
EDI
Development

SALES SOLUTION INTEGRATION
ORDER
STEELMAN – 3rd PARTY FINANCIALS
ORDER
ENTRY ATTRIBUTES
Promise
Dates
PROJECTED
SALES PRICING
CONFIRMED DYNAMIC
ORDER ROUTING &
COMMERCIAL
DRESSING PROVIONING
AP & RAW ALTERNATE
MATERIAL CTP & ROUTING PROVISONED
DEMAND
INVENTORY INFORMATION ROUTES
MODELER
Inquiry BASE BOM/
CONFIRMED Details FORMULAS
ORDER & ROUTES
STEELMAN
DATABASE
BUSINESS
OPTIMIZER ATP CTP
WORK
STANDARD
ORDERS
Status COSTING

ALTERNATE Ready Dates
PROVISIONED
MATERIAL PRODUCTION ROUTES Actual ALTERNATE
PLANNER PLANNER Production PROVISIONED
ROUTES

Inventory WIP LOAD
PRODUCTION INVENTORY BUILDING &
SCHEDULER SHIPPING

MES WORK
ORDERS ON
Dressed AR COST
Schedules PRODUCTION & GL VARIANCE
FLOOR Work Orders

STEELMAN EXISTING SYSTEMS 3RD PARTY FINANCIALS

CLIENT ORDER
ORDER ENTRY

PROVISIONING

PLANNING

STANDARD
COSTING DRESSING

PRICING SHIPPING
DOCUMENTS

SALES PRODUCTION
ORDER REPORTING

HEAT EXECUTIVE
BUILD REPORTING
FINANCIAL
STATEMENTS
SALES ORDER
MASTER PLAN FINANCIAL
PLANNING & MODULES
SCHEDULING WORK CENTRE
INTERFACE LOADING
TOOLS MAINTENANCE INVENTORY
WORK CENTRE
LINE-UPS
PRODUCTION
DATA
REPORTING

Steelman SEMS® Integrated Software Solution
Accounting GL, AR, AP, Financials Reporting

Partner Mgt Quotes-Sales Order Purchasing BI Reporting Tools
Customer-Vendor Contract Mgt Supply Chain Mgt
Business Intelligence
Reporting & Creation
Data Warehousing Options
Product Catalog Oracle Pricing & in SEMS system
Inventory Mgt 10g AS & DB Costing Models

Work Orders Distribution Plant Schedules Fabrication BOM
Provisioning Management Production Plans
Parts Mfg

Material Production Orders
Allocator to Orders & Recording Document Mgt
Claims Mgt
PDF, CAD, Photos,
Customer & Vendor MS-Office Docs, Scanned
Packaging
QA and Test Mgt Images
CAR –Corrective Actions
Heat Management
Reporting Load Planning
ISO Standards Compliances Shipping-Logistics Mgt
Constant Improvement
Programs Invoicing / BOLS / Ack / Mill Certs


Sales Order Management
Financials • Inquiries, Blanket and Spot
Orders
Customers
Customer Sales Order Internet • Repeat Orders search and
Management Management Phone retrieval
EDI/XML
• Offerings
Product
Catalog
Oracle
Standard • Auto Pricing/costing with
10g AS & DB
Costing manual override
• Tracking of Order changes
Work Distribution Production • Tracking of Inquiry
Instructions Management Management expiration
Material
• Real-time Order status
Allocator • Inter-co sales or transfers
• Customer self service
• Privilege driven security

SEMS Master Contract Management
Create Master Releases Mgt
Product
Contract with Products Against
Processing Work
Customer Specifications Period
Instructions
Define Period & Pricing Distribution
Configuration
Distributions demands

Purchase Orders
Created
For Distributions
Master Contract Mgt Screen
Manages-Reviews all functions
Production
Orders &
Status for
Distributions

Packaging,
Sales History Shipping Scheduled Master
Inventory
Claims mgt Status Sales Order
Allocations
Contract Invoicing, BOLs Confirmation
Credit Mgt


Master Order – Contract Mgt


Quotes/Sales Management
Product Specs
Create Quotes
Review Sales History Shipping Instructions
Change to Sales Create Work
WINS-LOSSES Promised Delivery
Orders Instructions
Inventory Available Dates –CTP/ATP
Firm Orders
Price Order

Create Provisioned
Route or BOM

Inventory
Allocation

Production
Finalized
Release to
Work Order
Schedule Order Plans
Manufacturing Confirmation Schedules


Quotes & Sales Order Header


Sales Order Line Items


Customer Management
Financials • Communicate to customer
in their “language”
Customer Sales Order
Customers
• Customer preferences
Management
Management
• Customer part definitions
• Customer based pricing
• Hierarchical corporate
Product Oracle Standard
Catalog 10g AS & DB Costing
structure
• Multiple Bill-to/Ship-to per
Work Distribution Production Sold-to
Instructions Management Management
• Multiple units of measures
Material • Multiple currencies
Allocator • Link to AR for credit control
• Integrated issue resolution
with claims management

Product Catalog
Financials • Attribute Based (Not SKU
based)
Customers
• Flat or hierarchical structure
Management
Management
• Track by weight, pieces,
linear measure or square
Product Oracle Standard measures
Catalog Costing
10g AS & DB
• Full steel-industry specific
product specifications:
Work Distribution Production
– Product type; end-use
Instructions Management Management – Multiple product shapes
– Dimensions & tolerances
Material – Grade, quality, industry
Allocator standards
– Chemistry
– Predefined /special tests &
processes

Demand Planning Purchasing Management
Review Demands Create Purchase Optimize
From Customer
Product-Customer Order & Pricing Product
Sales History
Use Forecasted Purchasing
Projections
Demands for Using Mill Pricing Orders
Linked
Purchasing Agreements Due to Demands

Review
In-transit
Purchase
Orders

Receive
GL & AP Orders
Postings Into
Supplier-Shipping Inventory
Invoicing mgt

“Tag # assigned”
3-Way Save to Inventory Costing Verified
Inspected
Matching Of Allocations to Orders Material
Tested
Invoices- P.Orders & Warehouse Mgt Transportation
Mill Certs
BOL.s Freight mgt Surcharges
Properties added


Demand Planning 5 Ws

• What to buy?
– Grade, Properties, Dimensions…
• When to buy?
– Time phased, forward looking
• Where or location requirements?
– By department, regional demands
• What we have in stock
– Free and allocated
• And, What Quantities to buy?

Inventory Control Demand Plans


Work Instructions
Financials • Dynamic Routing and
Provisioning
Customers
• Technical & commercial
Management Management instructions are added
• Instruction can be manually
Product Oracle Standard over-ridden
Catalog Costing
10g AS & DB
• Processes are user
definable
Work Distribution Production • Stock allocation using
Instructions Management Management intelligent attribute-based
search
Material
Allocator
• Outside processing
• Allows to provide realistic
ATP & CTP

Production Plans Cutting Planner


Standard Costing
Financials • By line items for all inquiries and
orders
Customer Sales Order • Table driven:
Customers
Management Management – Unlimited cost buckets
– User defined cost types and rules
Product Oracle Standard • Shop floor activities are applied to
Catalog 10g AS & DB Costing individual Orders
• Cost of WIP is accumulated
based on Level2 Data
Work Distribution Production • “Actual vs. Standard” variances
include:
– Efficiency variance
Material
Allocator – Material usage variance
– Material price variance
• GL booking by cost types
available for further analysis

Distribution Management
Financials • Record production results
• Track physical locations
Management
Customers • Maintain history of all
Management
transactions
• Store heat chemistry and test
Product Oracle Standard
Catalog 10g AS & DB Costing
result on items
• Trace tag genealogy back to
original heat
Work Distribution Production • Create customized shipping
tags by customer
Material • Dispatch shipments
Allocator • Generate BOL, Invoices and
Customs documents
• EDI, RF & barcode enabled

Logistics Load Shipping


Issue to resolutions

• Online claims
SALES
management
• Each department is
dealing with same
customer record
• No need to waste
SUPPLY
time
SERVICE
CHAIN • Sales and service
work together to
generate income

Claim Management
Claims can
be generated
claimed material can
for any
be marked for return,
shipped tag
for credit or rejected
and invoice

Multiple
defects per
tag, using
industry
standard or
customized
codes

Complete
logging of all
stages of
investigation


Oracle Database & Application Servers

STEELMAN STEELMAN
Applications Data

Content Advanced
Management Search

Browser/
Business
Device Intelligence

Collabor
ation
Tools

Workflow

Oracle10g Oracle10g
Application Database
Server in a Level 2 Server in a
Cluster MES RAC


Built-in Business Intelligence
Analyze Data In Real-time
• Industry leading, award
winning reporting / analysis
tool
• Management and operational
info on the fly
• No programming required
• Drill-up; drill-down capabilities
• Powerful, yet easy to use
• Reports can be incorporated
into system once developed
• Export to excel & other file
formats

Key Module

• Business Partner Management (BPM)
• Product Configuration
• Sales Management
• Production Management
• Warehouse Management
• Costing
• Shipping
• Claims Management
• Quality
• Reports and Business intelligence

Proposed Solution – Business Flows

• STEELMAN Steel Enterprise Management
Systems®
– Order to Cash
• Configure Quote to Order
• Order Management
• Routing Provisioner
– Forecast to Plan
• Advanced Planning and Scheduling
– Plan to Build
• Process Manufacturing
• Caster Sequencing
– Call to Resolution
– Business Intelligence


Order
Customers
Management Suppliers

Collaboration

Web Store Planning
Price
Configure
Call Center Check Purchasing
Availability

Sales / Quotes Tailorable, Manufacturing
Capture
Workflow
Driven Schedule
Service Process Finance

Contract Invoice/ Warehouse
Release Payment Plan Management
Ship & Shipment
Transportation
XML/EDI Track
Management

Multi-Channel Demand Complete Business Flow Integrated Logistics


Advanced Planning

Supply Chain Intelligence

Demand Planning
Planning level

Inventory Optimization

Supply Chain and
Manufacturing Planning

Order Promising

Manufacturing
Scheduling

Supply Chain
Collaborative Planning
Event Management

Minutes Hours/Days Weeks/Months Quarters Years Time


Process Manufacturing
Capture
Schedule Analyze Quality
Customer
Production Auto-Allocate
Demand

Create Procure Capture Costs;
Sales Order Materials Analyze Variance

Create Recipe Produce
Batch Ship Product
(if custom)

Manage Regulatory Update
Assign Lots
Documents AR / GL

Closed-Loop Demand to Build Offering


Close the Loop On Your Business

• Reduce redundant data
Maintain
entry & maintenance
Finance Maintain
Sell • Real-time visibility across
enterprise
Order • Built in business
Ship intelligence tools
Plan • Web deployed
Fulfill • Infinite scalability with
Procure Oracle infrastructure
Manufacture
• Integrates to ACCPAC or
ORACLE financials


Project Management

Daniel Brody
Project Director


Methodology: ERP/MES Project Lifecycle

Step 1: Discovery
• The first step in Steelman Software Solutions‟ ERP/MES project lifecycle is to work with our clients to develop a strategy for incorporating
MES into their enterprise. Our „SEMS System Assessment‟ allows clients to discover and define their ERP/MES strategy in terms specific
to their operations, while at the same time ensuring that all potential areas of improvement are identified.

Step 2: Framing the Solution
• Once the ERP/MES strategy has been identified, it is time to move towards framing the solution. This involves:
• Defining Functional Requirements
• Defining System Architecture
• Prototyping any GAPS discovered in the initial Discovery phase
• Developing an Implementation/Project Plan
• Developing a Change Management Plan

Step 3: Implementation
• Once the strategy has been developed and the framework designed, it is time to implement. To keep costs at a minimum, while ensuring
a seamless solution, Steelman Software Solutions follows a very structured implementation methodology that includes:
• Detailed Design and from a Process Design using Business Process Improvement methodologies
• Functionality Testing including database, hardware, network, and processes including work flow analysis
• Data Conversions
• Installation
• Training
• Support including a web site for Project Management, Metalink reporting site for SEMS issue resolving and client needs and custom job
planning, tracking tools and scheduling interfaces with our support/development team.


Steelman’s Services for Success

18 to 24 month project implementation estimate
Depending on number of unique lines of business


Delivering Results

• On time
• On budget
• Meeting or exceeding
expectations
• Quality control
• Integration
• Versatility
• Standardized product


On Time

• Understand Needs
• Have a standard
approach
• Projects/Tasks/Sub tasks
definition
• Be realistic
• Plan ahead
• Great Communication
• Hands-on testing and
training


On Budget

• Document requirements
in discovery
• Simulate real life events
• Consult on best practices
• Experienced project
leaders
• Detailed estimates
• Real understanding
• High-quality development


Meeting or exceeding expectations

• Quality control at all
stages
Preliminary Scope CRS
• Close collaboration –
Metalink
• Insight and standard
Implementation SRS versatility of SEMS
• Prototyping
• Added value
Testing Prototype


Quality Control

• Do the right thing ..right
• Realistic test suite
BA • Detail testing pre system
design
Customer Developer • Quality process
• Communication
• Standards
QA CAB


Versatility

• Configuration options
• Site flags
• Enhancements
• Collaboration
• Prototyping
• Best practices


Standardized Product

• One code set
• Release control
• Version Control
• Standard UI
• Documentation
• Development process


Summary

• State-of-the-art technology
• Steel-specific screens, features & workflow:
– Easy to train; no cultural shocks
– Fast implementation; no major tweaking as in the
case of “Vanilla” ERP system
• Scaleable, customizable, and attribute based –
important criteria for interface to
• Perfect fit – Steelman provides all the missing
pieces Your needs


Metal Software That Changes With Your Business

Know More.
Do More.
Spend Less
“EMPOWERING YOUR TEAM”


Steelman SEMS EBS Addon for Mills

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