AST Big-Bang rollout in KwaZulu /Natal

AST KwaZulu/Natal, a division of the AST Group, recently completed the redevelopment of all the core production application systems for Iscor`s large integrated Profile Products Steelworks in Newcastle. This project once more confirms the effectiveness of the highly successful "Big-Bang" strategy that the group originated and implemented for the first time at ISCOR.

"This was a huge development project," says Harry van Dam, AST KwaZulu/Natal regional manager. "It took over 400 000 man-hours, spread over almost three years to complete. The completion of such an ambitious project depended on outstanding project management and the full commitment of each team member under extremely demanding circumstances."

Van Dam continues, "However those factors on their own would not have been enough without the full co-operation of our clients at both management and grass roots level. It was because we were able to combine all these essential elements that we were able to accomplish this large and complex undertaking so successfully."

"Most of the functionality of the new systems is either completely new or significantly different from previous applications," adds van Dam. "The new applications combine functionality such as capacity planning, order acceptance, optimised capacity utilisation across several plants/production units, scheduling and despatch management into an integrated system."

The new client-server systems are event driven for Windows 95 clients while the servers are Unix based with Oracle as the database. There are over 850 different user windows, with complex dialog flows, more than 800 database tables and over 450 predefined reports.

In addition, most of the infrastructure was replaced at a cost of over R30m. This involved phasing out obsolete mainframe equipment, designing the new infrastructure, installing new Unix server equipment and upgrading the Wide Area network together with more than twenty Local Area Networks and over four hundred user workstations.

"Several factors were involved in Iscor Profile Products replacing the previous systems and infrastructure," van Dam adds. "The old applications could no longer meet the increasing demands of a highly competitive international steel market, which dictates more flexibility and reduced stocks while at the same time improving lead times for customers.

"Also, the old systems could not provide the high levels of integration needed to supply up-to-date interactive information at all times. On top of this the mainframe equipment in use became obsolete and could no longer be upgraded, which resulted in production delays The new infrastructure will also provide a large capacity RAID system with redundancy in critical areas."

The new systems will save Iscor several million Rand per month in costs through improved plant utilisation, lower stock levels and reduced labour requirements. In addition, significant improvements in order lead times and customer service are now possible.

"Normally an application systems project of this magnitude is done in phases to reduce the risk involved and minimise the impact on the production and business processes of the client," comments van Dam. "However in this case we could not do that, firstly because of the high level of integration required between the various sub-systems and because the old mainframe simply could not cope with the volume of interaction required between old and new systems.

"The only effective and practicable way we could accomplish this was to first complete all development work and then roll out all the subsystems in one tremendous effort, which of course led to the project being given its nickname of `Big Bang`."

During the actual implementation the main systems were off-line for three days for the data conversion process, but Iscor Newcastle was able to maintain production and despatches at all plants at near normal levels throughout. During the phasing in of the new systems and final set-up only minor delays were experienced.

High levels of co-operation between AST staff and Iscor personnel ensured that backlogs in captured data were eliminated and normal operations were achieved in record time.

Big Bang phase 2, which involves a number of smaller projects, is now being planned to round off the new systems. Two such projects are to establish a dedicated full-time support team through cross training and the archiving of information after specific periods as dictated by business, legal and other requirements.

Small, dedicated teams who were involved in the original project will manage these projects, capitalising on the skills and experience they built up over three years.