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Níall Ó Cinnéide17th October 2018
Connecting Top Floor to Shop Floor Preparing for the Factory of the Future at SKG
Connecting Top Floor to Shop FloorInspirational Quote Adjusted Slightly:
‘”Technology is nothing. What’s important is that you have faith in people, that they’re basically good and smart, and if you give them tools, they’ll do wonderful things with them.” - Steve Jobs -
What’s also important is that you have faith in people (and align a lot)‘”Technology is nothing quite important.
(and creative problem solvers)
3
• SKG at a Glance• SAP Solution Landscape• Choice of SAP MII • Solution Architecture• Achievements & Benefits • Lessons & Recommendations • The Future
SKG At a glance
4
EUROPE AMERICAS
EUROPE TURNOVER
N O . 1
8.6
ONLY
N O . 1 €
in corrugated boxes & kraftliner container board
Pan-American producer of containerboard & corrugated
billion in revenue in 2017in Bag-in-BoxTM
Geographic reach
5
EMPLOYEES CONTINENTS COUNTRIES FACILITIES CUSTOMERS
346,000 35 64,000370
Our breadth of operations…This Presentation’s Focus is on PaperWho we are
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FORESTRY
103,000hectares forest
plantation
RECYCLING
6.2 Milliontonnes per annum recovered paper
PAPER
7.0 Million tonnes per annum
PACKAGING
10.8 Billion m2 per year
SAP SCM for Supply Chain. SAP ECC for FI, CO, MM, PM,
WM, PP, SD, VC. SAP BW/BI for reporting.
Connecting Top Floor to Shop Floor
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Scope: Solution Landscape for Mills
ECCERP Central Component
BIBusiness
Intelligence
SCMSupply Chain Management
GreyconX-trim
MIIManufacturing Integration & Intelligence
PCoPlant Connectivity
HistoriansE.g. OSISoft
Other Shop floor E.g. QM SQL DBs
SAP MII for Production Execution & Quality Management.
SAP PCo for alerts and data acquisition.
POProcess Orchestration
Legacies
Other Non-SAP
SAP PO for integration with legacy info systems.
It’s an SAP product. Flexible tool set for building
composite applications on common foundation.
Flexible architecture (centralised and/or at the sites).
Connect once, reuse many times e.g. historian is used for multiple composite applications.
Templates by SAP & 3rd parties e.g. batch manufacturing, CBM.
Matches our internal competencies.
Connecting Top Floor to Shop Floor
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Why SAP MII? Drivers & Decision – Robust, Flexible, Efficient, Supported
Integration with other SAP Products
MII
E.g. Historians, PLCs
MII Front-End MII Data Store (SQL)MII Business LogicComposite Application A: Production Execution
Composite Application B: Quality management
Composite Application C: Condition Based Maintenance
PCo
E.g. Vibration Monitor E.g. QM, SQL DBs
Connecting Top Floor to Shop Floor
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Solution Architecture: Understanding & Bridging the Layers
Establishing the principles:• Understand the nature of the
data/how it is organised.• Understand the audience and
use of the data.• Agree what goes where.
DCS Distributed Control System
Display, Set and Exchange Data
Historians Data Store & DisplayTime Series/Persistent
MII Data StoreRelational/Dynamic
OPC Server Data Exchange
PCo Data Exchange
OPC = Open Platform Communications
There are exceptions:e.g. A layer is sometimes skipped.e.g. Data sent from MII to Historian.
PLC Programmable Logic Controller
Monitors & Controls Things
MII
Connecting Top Floor to Shop Floor
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Achievements: Scope of Main Functionality Implemented…More in the Pipeline
ECC
Shift book
Notifications
Messages/Instructions
Time Loss
Checklists
Ad-hoc Data Acquisition
Shift Calendars
BIReporting
Dash-boarding
Quality Management
Quality Targets
Laboratory Input
Paper Profile
Status Management
Worklists
Inheritance
Production Execution
Blocks/Cut Plans
Recipes
Live Costing
Machine Settings
Production Registration
Winder Queue
Shop Floor/Other
Historians/PLCs
Autoline/Paperlab
Weigh Scales
Winder/Core Cutter
Conveying
Other
SKG common MES with automated data acquisition (background). Deep integration with SAP ECC e.g. BOMs, Routings, Functional Locations…
Connecting Top Floor to Shop Floor
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Achievements: …Immediate and Easy to Use
Connecting Top Floor to Shop Floor
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DEEP & NEAR REAL-TIME INTEGRATION OF
SYSTEMS
BEST CONCEPTS AVAILABLE IN ONE SOLUTION FOR ALL
AUTOMATED DATA COLLECTION
ONE SOURCE OF TRUTH & VISIBILITY
PROCESS HARMONISATION &
GOVERNANCE
Business Benefits - Standardised and Harmonised Platform with Bench Marking in a Paperless Environment
Connecting Top Floor to Shop Floor
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SKILL SET REQUIRED IS EXTENSIVE E.G. MII,
ECC, OPC, SQL, HTML, PLCS, PROCESS
CONTROL, ETC…
NEED TO MANAGE CHANGES
THROUGHOUT MULTIPLE SYSTEM
LANDSCAPES
TESTING CAN BE ‘EXCITING’ AS OFTEN
WITH ‘REAL/LIVE’ DEVICES...
CHALLENGING TO ENSURE TEST
SCENARIOS COVER ALL POSSIBLE CONDITIONS
END USER TRAINING IS QUICK AS SOLUTIONS
ARE INTUITIVE
Lessons Learned: Implementing SAP MII is Different…
Connecting Top Floor to Shop Floor
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NEED TO HAVE COMMON LANGUAGE, UNDERSTANDING AND
STRATEGY
DATA IN THE SHOP FLOOR IS OFTEN
IMPLEMENTED USER CENTRIC & NOT
ENTERPRISE CENTRIC
EACH SHOP FLOOR DEVICE CAN BE
DIFFERENT - EVEN WHEN THEY LOOK THE
SAME MAKE
RELIABILITY OF SENSORS…NEED TO BE
ABLE TO ADD CORRECTIONS
DON’T TAKE ANYTHING FOR GRANTED
E.G. TIME STAMPS & TIME CHANGES
Lessons Learned: Getting Enterprise Suitable Data from Shop Floor Systems.
Connecting Top Floor to Shop Floor
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Align
Understanding:Scope, roadmap,what goes where,who does what.
Involve
Stakeholders from all strata: lines of
management, SAP experts, local IT, process control.
Explore
Quickly kick over the rocks: connect to the shop floor, make sense of the
data and monitor it.
Iterate
Iterative not waterfall…multiple
development cycles, frequent testing and
feedback.
Contingency
That what is automated, should
also be possible manually.
Recommendations: People, Exploration, Iterate and Backup
Connecting Top Floor to Shop Floor
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Insights
More data, more visualisation,
more insights.
Integration
Further integration of information
system processes.
Optimise
Semi/automatic optimisations within
governed parameters.
Predictive
Continue evolve from real-time and condition based - to
predictive.
Cloud/Edge
Cloud services to generate further
insights and deliver value through Edge
processing.
What comes next?
Connecting Top Floor to Shop Floor
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Thank You for Listening to Our Journey So Far…Any Questions?
Questions?