1308 Shop Floor Basics Using SAP ME(3)

Shop Floor BasicsSAP Manufacturing Execution

17th May 2011 @ ASUG

© 2011 SAP AG. All rights reserved. 22

Learning Points

Overview of SAP Manufacturing Execution (ME)

Learn how SAP Manufacturing Execution integrates disparate systems with shop-

floor activities to create a single, comprehensive production record that is an

aggregate account of the entire product history

How you could utilize SAP Manufacturing Execution to capture, share, and store

manufacturing data


Agenda

SAP ME Business Value

SAP ME Overview

A Day in the Life on the Shop Floor

Turning Data into Information – Reporting and KPIs

SAP ME to ERP Integration

Future Innovations

Q & A

SAP ME Business Value


Recovery and Global Restructuring

Efficiency& Margin Pressure

Macro-Economic Data Drives Global

Restructuring

Collaborationis Key

Trends

Impact

Return to Quality

Increased Margin

Pressure

Margin expectations

increase

Profitability restored

via higher productivity

Expectations higher in

emerging markets

where growth is

Network

Complexity

Product innovation

focus

Complex partner & JV

networks

Hybrid Internal and

Outsourced

manufacturing

Restructuring in

Supply and Demand

Emerging Market

Dominance

Trade balances and

currency valuation

Cost Structures and

Competition

Brand and

Regulatory Impacts

Highly visible product

recalls

Traceability and food

safety

Increased and

uncertain regulatory

climate


Global Manufacturing Is Challenging: Adapt

Profitably, Quickly, and Consistently to Demand

Can’t improveExecution

VP Manufacturing

VP BU

CIO

VP OperationsVP Sales

Can’t measure Performance

Can’t see Production Status

Can’t measure Performance


Put the Manufacturing Plant in Context

Design View

VP, R&D

Manufacturing

View

VP Manufacturing

Outsourcers

Contract Mfg

Suppliers

Internal

Plants

Supply Chain View

VP Supply Chain

Demand SensingAfter-Sales

Service

Delivery

LogisticsManufacturingSourcing

Supply

Planning

Sales &

Marketing

NPDI

Portfolio

Management

Innovation

Management

Internal Plant View

Plant Manager


Plant-to-enterprise visibility Complete visibility across plants

Quick adjustment to change, exception,

and quality issues

Optimal productivity and utilization of

resources and assets

The Perfect PlantHarmonizes Complex Manufacturing Network Interdependencies

Global coordination Up-to-date schedules

Complete traceability,

quality, and compliance

Real-time event

notifications and response

Local execution Detailed production plans

Identification and resolution of

constraints to maintain optimal

production

Optimized work in progress (WIP)

in response to reduced lead times

Reliably produces to targets and delivers continuous improvements in cost, quality, and responsiveness


Aerospace &

Defense

High Tech Automotive

& Auto

Electronics

Medical DeviceIndustrial

Machinery &

Components

low volume/high mix

build-to-order assembly

high volume/low mix

repetitive manufacturing

Industries served with SAP Manufacuring Execution


SAP Manufacturing ExecutionData & Processes

Stand-alone Manufacturing Execution System (MES) with “out of box” integration to ERP for discrete manufacturing

Detailed definition of production processes, and dynamic control of WIP execution

Real-time production information

Product and process quality improvement:

Role-specific provisioning of relevant information

Zero-defect production

Compliance with internal and external regulations

Serialized Component Traceability

Full Integration between shop floor and enterprisePlant /Machine Data Collection Time recording

Machine connectivity

Production monitoring (WIP, OEE, Yield, Line

monitor, machine status, etc.)

Production-Reporting & Dashboarding

Enterprise Integration (ERP, PLM, etc.)

Production and Process Management Process definition and work instruction

Process enforcement and data collection

Paperless production (Operator Terminal)

Alarm/Event Management

Quality Management & Traceability Tests & SPC

Defect recording and Non-conformance

management

Serial number / Batch / Time-based material

Traceability

Process-Traceability


What is SAP Manufacturing Execution?

SAP ME is an application, not toolkit Ease of use/usability with configurable GUI

Built-in business rules and logic

Configurable system rules

SAP compliant Product Solution Validation

Product Standards

Ramp-up Process

Built on J2EE Architecture

SDK for Extendibility Extend product capabilities

Upgradeable product extensions

Support partners and customers

Product Configuration SAP Technology Stack

Integrated or standalone

SAP NetWeaver, SAP MII (limited license), Pco, SAP ERP Content included in product

BusinessObjects for reporting is separate

Enterprise Grade Software – Will scale as business grows


Typical Scenario

“Standard” Electronics Line

• Highly Automated


Typical Scenario – The Requirements

Requirements

• Control Required



Requirements


• Data Collection Required



Requirements


• Data Collection Required

• Data Feed Required


DISCRETE MANUFACTURING (HISTORICALLY)

Shop floor fabrication and assembly processes run and managed by isolated applications:

Excel spreadsheets

Access databases

Niche vendor applications

RESULT:

Individual silos of manufacturing operations and data

Enterprise disconnected from shop floor – decisions based ontheory, not actual data

Operational inefficiencies, lostproductivity, wasted materials, etc.

Traditional Traceability


Does This Look Familiar?


Product & Customer TraceabilityVisiprise MES &

SAP ERP

ERP

Customer

Plant Floor

Suppliers

SAP Manufacturing

Execution &

SAP ERP

Product & customer

traceability

Internal & customer traceability, global enterprise, “As-Built & As-shipped”,

downstream supply chain


Full Supply Chain Traceability Visiprise MES,

SAP ERP & Quality

ERP

Customer

Plant Floor

Suppliers

Quality

Management

SAP Manufacturing

Execution, SAP ERP &

Quality Management

Entire supply chain

traceability

Entire supply chain traceability, preventative action, responsiveness

SAP ME Overview


SAP Manufacturing Execution - Solution Suite

Production Metrics (BOBJ)

Test and Repair

SAP Manufacturing Execution

Manages and controls manufacturing

and shop floor operations

Integrates business systems to the

shop floor

Complete component and process

traceability across global operations


SAP Manufacturing Execution Functionality

• Operator logs into an operation and a machine and selects a unit to work on

• Operator Dashboard configured to present the operator with only the information that’s needed to perform this job on this unit

• Material consumption

• Data collection

• Diagrams/Documents

• Dashboard enforces correct operation, machine status is correct, operator is certified; process is enforced, data is collected, and next step is determined based on outcome



• Operator logs into an operation and a machine and selects a unit to work on

• Operator Dashboard configured to present the operator with only the information that’s needed to perform this job on this unit

• Material consumption

• Data collection

• Diagrams/Documents

• Dashboard enforces correct operation, machine status is correct, operator is certified; process is enforced, data is collected, and next step is determined based on outcome

Unit-Level Tracking

Material Consumption

Data Collection

Visual Instructions


Integrated Work Instructions and Assembly Data


Data Collection


Process Enforcement


Device History Report — Unit-Specific, As-Built Data


Device History Report — Unit-Specific, As-Built Data

(cont.)


SAP ME: SDK (Java)

Develop new SAP ME functionality as well as

extend current functionality to support

customer specific requirements

Leverage published API and Web Service

libraries

Facilitate and control customization projects

using other supported tools such as source

code control products

Key Features

Empowers partners and customers to build

their own customizations

Intended to preserve customizations during

the upgrade process

Supports new service packs and patch

releases thereby reducing cost

Reduces overall risk when customizing and

upgrading

Key Benefits

A day in the life on the shop floor


Multiple Roles — Same Product

Shop Floor Operator

Manufacturing Engineer

Quality Engineer

Production Supervisor

Plant Manager

Program Manager

VP of Operations

CXO


Meet the Team:

Meeting the production

schedule

Maximizing production

Number of good units

produced per shift

Minimizing downtimes

First Pass Yield

Asset Effectiveness

Escape prevention

Production Efficiencies

Quality and Compliance

Global Standards

Dave Downs

Production Manager

Charlie Greene

Line Technician

Peter Chang

Quality Assurance Manager

Jane White

Plant Manager


Release of Production Orders


SAP Manufacturing Execution at Work:

Charlie Green – Worker


Component Assembly


Manufacturing Process Compliance


Real-time Datacollection and Analysis


Error Proofing and Quality Gating

Prevent Escapes – Check for open Nonconformances

Prevent work against jobs on hold – Value Add verification

Verify correct operator with up-to-date certification

Correct Material consumed at specific times

Material, Machine, Man, MethodNo defects, No breakdowns, Correct operator, Defined Process


Production Analysis


SAP Manufacturing Execution 5.2 Review

RTC: 18 June 2009

• Time Sensitive Material (TSM)

• Floor Stock Management (FSM)

• Overall Equipment Effectiveness (OEE)

• Tool Management (TM)

• Production Metrics Powered by Business Objects (SAPMEBOBJ)

• Globalization

• Software Development Kit (SDK)

• ERP Integration (SAPMEINT)

Turning data into information –

Reporting and KPIs


SAP Manufacturing ExecutionVisibility and Analytics

Enterprise Level Plant Level

Dashboards Dashboards Reporting

Link production data with

information from enterprise

systems

Benchmarking and Reporting

across plants

e.g. OEE Report

Drill-down

Plan vs. Actual

KPI-Cockpit according to VDMA

66412 standard

Packaged solution from SAP

Consulting

14 pre-defined Business Objects

Universes

25 pre-defined Reports with

Business Objects Web Intelligence

Ad-hoc Reporting with Business

Objects Explorer


SAP ME Reporting Infrastructure

BOBJ

14 Universes

25 Reports

JSP

Audit Log

Reports

JSP Reports

50+

MII

Visualization

BOBJ

14 Universes

25 Reports

44© SAP 2007 / Page 44

Business Objects Web Intelligence

BusinessObjects Web Intelligence allows users to

Run, copy and edit predefined web intelligence reports, scheduled and on demand

Perform ad-hoc quiries and create new reports

Modify and extend universes with Business Objects Universe Designer software

Translate universes with Business Objects Translation Manager

45© SAP 2007 / Page 45

Viewing ME ODS Reports using BusinessObjects Web

Intelligence XI 3.1

46© SAP 2007 / Page 46

Overall Equipment Effectiveness (OEE) Report with MII

Overall Equipment Effectiveness (OEE) report considers the availability,

performance, and production quality of a machine or production line to

determine the net or true efficiency of that machine or production line.

OEE Report Results Properties

By Hour, Day, Week or Month

Each value is displayed as a

percentage (%)

Actual vs. Target OEE

Display and Filter Options

Written in MII and pulled from WIP

SAP ME to ERP Integration


SAP Manufacturing ExecutionOut-of-the-box Integration with SAP ERP

ME/ERP Integration

Pre-defined interfaces End-to-end process integration

Communication based on Web Services,

BAPI, RFC

Using SAP MII as integration platform

Seamless end-to-end process integration

between ME und ERP

Can be extended with customer-specific

scenarios


Fully Integrated End to End Business Process

Management

Web

Service

SOAP

Web

Service

IDOC

BAPI/RFC

Manufacturing Integration

Manufacturing Intelligence

Web Service

SOAP

SAP JCO

ERP

SOAP

MII

Inbound

Web

Serv

ices

Security

Transformation

Workflow

Outbound

Message Enrichment

Message Format

Message Transfer

Message Callback

Asy

nch

ron

ou

sSy

nch

ron

ou

sEven

ts

ME

NWPCo


TcM

PLM

Adapter

• Production Order

• Planned Order

• Material

• BOM

• Routing

• Operation

• Material Classifications

• Inventory Receipt w/ Batch

• Inventory Reservation

• Equipment Scheduled Downtime

• UOM Support

• RMA Service Order

• Work Center

• HR User w/ Certification

• Production Yield Confirmation

• Production Scrap Confirmations

• Planned Order Backflush

• Planned Order Scrap

• Component Consumption

• Parent Batch Number

• Component Batch Number

• Equipment Unscheduled Downtime

• Equipment Usage

• Inventory Return

• Inventory Scrap

• Inventory Unreserved

• DC Batch and Batch Characteristics

• UOM Support

• RMA Service Order Complete

• Quality Notification

Master Data Authoring and Engineering Change Management

SAP® ME and ERP Integration

SAP ME 5.2 SP5

SAP Enterprise Resource Planning

Quality Management

Inventory and Warehouse Management

Plant Maintenance


WIP (Lot and Serial #) Tacking and Genealogy

Manufacturing Process Control

Defect Tracking and Resolution

Data Collection

Labor Tracking

Production Planning


Solution Enhancements Key Benefits

Plant Connectivity

New native connectors for

market leading applications;

Additional data

transformation and scripting

capabilities to push more

functionality closer to the

data source;

Continued investment in

OPC-UA (Unified

Architecture) to enable more

full featured interop

scenarios;

Partner SDK with

certification program;

Continued investment to

fully support other SAP

solutions (ME, ERP, EWM);

Plug-n-Play connectivity to plant applications and

automation systems;

Real-time monitoring for exception management;

Integration with SAP Solution Manager to simplify

administration of total solution landscape;

Native API connectors to market leaders for maximum

performance and simplest implementation

PLANNED INNOVATIONS

Future Innovations


SAP ME 6.0 New Functionality

RTC: June 15, 2011

Enhanced Security – UME

Configuration Data Transfer Tool

New Production Operator Dashboard

Shop Work Bench

Visual Test & Repair

Floor Stock Management

Sampling

Electronic Time Sheet

NetWeaver ADS Integration

Earned Standards

Message Board

2D Barcode

Operation Standard Labor Time Recording

Phantom BOM Support

Data Field List

DHR Improvements

Technical Enhancements

SAPMEINT Interfaces

USER EXPERIENCE, TCO, EXTENSIBILITY, NW ADOPTION, MULTI-INDUSTRY


SAP ME 6.0: New Production Operator Dashboard

Features

Modular plug-in and layout configuration

Highly configurable to meet the disparate

needs of the shop floor w/out custom coding

Transact at both the production unit and

operation levels

Filter work by production unit,

operation/resource, or work center/end item

number

Updated design to reflect modern “look and

feel”

Benefits

Modular configuration supports customer

process/workflow requirements

Support for multi-mode manufacturing in both

high volume and complex assembly

environments

Ease of setup and configuration allow a build

your own approach right down to the user


Extensibility

The ME domain object model for persistence will be

available for reuse to better support custom data objects

and services

New UI framework based on LSF (WPMF) for extensibility

– The plug-in/layout architecture enables small but non-

disruptive changes

PODs converted to WPMF (rest of app on older UI

framework)

New tool to generate web services from API PLUS

documentation and samples

– All new API’s will be available as web services

– Legacy web services hand coded and based on legacy

code)

– Backwards compatibility with legacy web services

maintained

Additional APIs (and web services) published

(approximately 500 in total)

Documentation for WPMF plug-in writing and API to be

included in SDK version 2.x

Extending EXISTING POD UIs can be done through

creation of plug-ins

– Existing core plug-ins cannot be extended

Security

NetWeaver UME integration (single sign-on)

Auditing

NetWeaver Administration Measurement Framework

integration

Import the measurements into the License

Administration Workbench (LAW) for consolidation

Solution Manager

New Solution Manager content added to cover 6.0

scope

TCO

Diagnostics

– New activities to be used by SAP Services and Support to

diagnose issues, particularly around transaction mgmt and

DB settings

Installation

– NetWeaver CTC integration to improve SAPMEINT

installation and configuration process

Database

– Consolidated ME DB scripts to reduce number of manual

steps to decrease potential errors

SAP ME 6.0: Technical Enhancements


SAP Manufacturing Execution: Key Capabilities

Serialized component traceability (as-built record)

Real-time enforcement of engineering changes,

quality, regulatory, requirements at the front line

Dynamic routing based on real-time in process

characteristics

Granular WIP tracking with additional level detail for

critical characteristics: revision level, quality status,

lot characteristics

Management of multi-level non-conformance

processes

Enterprise Grade Software – Will scale as business grows

Thank You!

Contact information:

Mike Lackey

VP of Solution Management

Manufacturing Execution

[email protected]

+1.404.643.2465

mailto:[email protected]