Linking Shop floor Machines to SAP for Real-time production information

Wayne Mcfadden

• Business Systems manager for SAP Warehouse

Management, Production Planning, Inventory

Management & Plant Maintenance

• 10yrs SAP experience

Agenda

• Who are Warburtons

• What IT do

• The Auto-Counting solution

• Integration issues

• The future

Agenda

• Who are Warburtons

• What IT do

• The Auto-Counting solution

• Integration issues

• The future

Who are Warburtons?

The challenges of a daily fresh

business

• Silo to Shelf in less than 24 hours

• No stock for all 100+ SKU’s made

fresh every day

• Make to Estimate/Order

• Deliver direct to 22,000 stores

• Nothing stand still for long !!

Agenda

• Who are Warburtons

• What IT do

• The Auto-Counting solution

• Integration issues

• The future

Our Landscape

SAP @ Warburtons2001

Business case to invest in SAP R/3 approved by Board

2002

SAP R/3 FI, CO and MM

2003

PP-PI & HR

2004

SD

2006

SAP BI

2007

Upgrade to SAP ERP2005

SAP ERP-Shop Floor integration piloted using Siemens Simatic-IT solution

2008

SAP SRM

2009

SAP WM Inter-company

SAP PP ISDPS - CE App for Bakery Scheduling

SAP Exchange Infrastructure (XI) to Process Integration (PI)

2010

SAP WM order picking

2011

SAP PM

The challenges of a daily fresh

business

Our current PP-PI solution

• Largely unchanged for 10 yrs

• User input based

• Standard GI GR

• Unloved and unliked

Operational processes

Stock Raw IngedientsConsume Ingredients

Create WIPConsume WIP

Create FG

Move FG stock into Shipping

Shipping noteReceipt into Stock

InvoiceDeliver / ASN / CDNWM Order pick

Agenda

• Who are Warburtons

• What IT do

• The Auto-Counting solution

• Integration issues

• The future

The Problem

• Stock in the system- Timely confirmations needed by users

- Breakdowns cause delays to onwards shipping

• Needs to be accurately counted- High volume, fast moving

- High amount of unaccounted losses

What sort of solution is it not?

The Solution

• Shop floor machine utilisation- Pre-existing stand alone product recognition systems

- Authenticated product basket counting

- Linked into SAP upwards only

• Real-time automatic confirmations- Recognition of basket leads to confirmation against process order

- Users don’t need to log in

- Close process order simplified

Warburtons solution architecture

PLC .NET SAP via RFC

The Benefits

• Near perfect stock reconciliation - Counts almost 100% correct all the time

- Always up to date

- Linked into SAP upwards only

• It just works- Users don’t even need to log in

- Remaining functions greatly simplified

Live Demo……

• hopefully

Agenda

• Who are Warburtons

• What IT do

• The Auto-Counting solution

• Integration issues

• The future

Integration issues

Integration issues

• Level 4 – Enterprise process- Standard IT governance

- Change control

- Transactional every X minutes

- Patching upgrades

• Level 0-2 – Shop Floor control- 100% up time

- If it’s broke, we don’t make product so it needs fixing

- Transactional every X miliseconds

Agenda

• Who are Warburtons

• What we do

• The Auto-Counting solution

• Integration issues

• The future

The Future

• Automate all production data entry- Accurate raw material consumption

- Real-time and accurate production efficiency and quantity

• Production plan to the production line- Centrally controlled production plan

- Updating the plan with actual

• Automated BOM change to SCADA- Less process control variance