SAP CLOUD FORUM 2017-ENDÜSTRİ 4.0& IoT CONNECTED MANUFACTURING

Endüstri 4.0 & IoT Connected ManufacturingFatih Kayadelen

SAP

May 25, 2017

SAP CLOUD FORUM Digital Business

2© 2017 SAP SE or an SAP affiliate company. All rights reserved.


Major shifts in the economy accelerate

the transformation to a Digital Supply Chain

• Customer Experience

• Local Manufacturing

• Networked Economy

• Changing Society


Connecting Things with People and Processes

Industry view

Line of Business

view

SAP Leonardo Portfolio

Technology view

SAP Leonardo

(“Things” View)

Digital Supply Chain

(Business Process View)

SAP Leonardo Innovation Portfolio

Digital Manufacturing


Digital

Business

Planning

Digital

Logistics

Digital

Product

Innovation

Digital

Manufacturing

Digital

Operations

Connected

Products

Connected

Assets

Connected

People

Connected

Fleet

Connected

Markets

Digital Supply Chain

SAP Leonardo

SAP Leonardo Bridge

Digital

Response

& Supply

Digital Supply Chain, powered by SAP Leonardo

Connected

Infrastructure


Trends Impacting Connected Manufacturing Internet of Things and Industry 4.0

SAP Connected Manufacturing runs industrial IoT with Industry 4.0 scenarios

Internet of Things

Internal INDUSTRIAL scenario External scenario

SCADA / HMI

Machine Layer

MES

ERP (PLM, PP)

» All industries

» All things and devices

» Ubiquitous

» Personalized

SMART Industrial

THINGS & DEVICES

Industry 4.0» Manufacturing

industries

» OT-IT convergence

» Systems, things, and devices on the shop floor

SAP Solutions for Industrial IoTSAP Connected Manufacturing

» SAP Manufacturing Execution on HANA

» SAP Manufacturing Integration and Intelligence on HANA

» SAP Plant ConnectivitySAP Solutions for External IoTSAP HANA Cloud Platform

» SAP HANA Cloud Platform (HCP)

» SAP IoT Connector

» SAP Plant Connectivity


ISA95 – High Level DescriptionL

evel

4L

eve

l 3

Level

2L

eve

l 1

Business Planning & LogisticsPlant Production Scheduling,

Operations Management, etc

Manufacturing Operations

ManagementDispatching Production, Detailed

Production Scheduling, Reliability

Assurance…

Batch

Control

Continuous

Control

Discrete

Control

Establish the basic plant schedule –

Production, material use, delivery

and shipping.

Determining inventory levels.

Work flow / recipe control to

produce the desired end products.

Maintaining records and optimising

the production process.

Monitoring, supervisory control and

automated control of the production

process

Sensing the production process,

manipulating the production

process.


Level

4L

eve

l 3

Level

2L

eve

l 1

Business Planning & LogisticsPlant Production Scheduling,

Operations Management, etc

Manufacturing Operations

ManagementDispatching Production, Detailed

Production Scheduling, Reliability

Assurance…

Batch

Control

Continuous

Control

Discrete

Control

Establish the basic plant schedule –

Production, material use, delivery

and shipping.

Determining inventory levels.

Work flow / recipe control to

produce the desired end products.

Maintaining records and optimising

the production process.

Monitoring, supervisory control and

automated control of the production

process

Sensing the production process,

manipulating the production

process.

ISA95 – High Level Description


Internet of Things and Industrie 4.0SAP Connected Manufacturing Data Life Cycle

SCADA / HMI

Machine Layer

MES

ERP

1

Alerts

SPC

KPI’s

Production

Analytics

Predictive

Business

Global

MII

WiP

SA

P B

I

SA

P P

A


SAP Digital ManufacturingIndustry 4.0 meets Internet of Things

Connecting production systems to core business processes with an end-to-end visibility

Challenges BenefitsSAP Digital Manufacturing

Lot Size One Quality

Requirements

Extreme

Variability

Manual

Processes

Rapid

Innovation

IT-OT

Convergence

Improvement in

OEE

First Pass

Yield

Increase in

Product

Throughput

TraceabilityProduct

Network

Faster Order

Creation

Connected

Assets

Plant

Connectivity

Smart Data

Streaming

Augmented

Reality

S/4HANA Manufacturing Execution Suite

23% 99.5%

15%

HANA

30%

© 2017 SAP SE or an SAP affiliate company. All rights reserved. 11This presentation and SAP‘s strategy and possible future developments are subject to change and may be changed by SAP at any time for any reason without notice.This document is provided without a warranty of any kind, either express or implied, including but not limited to, the implied warranties of merchantability, fitness for aparticular purpose, or non-infringement

Customer

SAP Digital Manufacturing

Enterprise Visibility - Digital Twin Strategy

https://video.sap.com/media/t/0_0q0tvdon

https://video.sap.com/media/t/0_0q0tvdon


Digital ManufacturingLinking the physical world to the digital world

Physical WorldDigital WorldBusiness World

General Ledger

Procure to Pay

Order to Cash

Engineer to Order

Configure to Order

Make to Stock

Inventory Controls

Costing

CRM

SRM

Materials

Digital Twin

LIMS/Inspection/

Equipment Testing

AutoVending

Machine

Engine

DCS/PLC

Sensors

Robots

Pumps

Weigh Scales

CNCs

AGVsMotors

“Performance”

“As Maintained”

“As Built”

“As Designed”

Chemicals

CPG

Batteries

Drinks

€$

£

¥



From Internet of Things to Business Outcomes Across the Value Chain

R&D / MRP Sales Manufacturing Aftermarket ServiceSupply Chain

From Top Floor to Shop Floor and out into Manufacturing Networks

Partner

ApplicationsCustomer

Applications

SAP

Applications

Machine Connectivity

IoT

Applications

Collaborative

Applications

Predictive/ Prescriptive

Applications

Connected Manufacturing connects the worlds

of machines and business via:

• HCP for IoT

• open APIs

• easy connectivity

It is an open platform of Industrie 4.0 grade

manufacturing solutions

• Open to non-SAP apps and non-SAP back-

ends

• Following the OPC UA Standards

• Enabling a vibrant manufacturing network

• Connecting partners along the supply chain


SAP Digital Manufacturing Industrial IoT

» Multiple vendors

» Multiple machines

Connected Manufacturing

SAP ME

SAP MII

SAP QIM

SAP CAMS

SAP PCo SAP OEE

Connected Manufacturing

SAP ME

SAP PCo

SAP MII

Asset Intelligence Network

Distributed Manufacturing Network

OEM Cloud(Mindsphere)

S/4 HANAEnterprise Management

» Business Context

» OEE, Energy Management


Machine

Cloud

IoT Cloud

SAP Digital ManufacturingOverall Solution: Cloud / On-Premise / Shop Floor

SAP Manufacturing Execution Suite

Automatic Data Entry (Machine Connectivity)

Shop Floor

LIMS SCADA / HMI

Plant Data

CollectionWireless

Integration

Environmental

Building Management

Plant

Historian

Plant DBDCS

PLC

Logistics

Sensors

Po

we

red

by S

AP

HA

NA

Machine layer

Process & Production Planning

Predictive

Maintenance

SAP Fiori

On-premise / Cloud

Asset

Intelligence

Network

AnalyticsSAP Integrated

Business Planning

SAP

Hybris Ariba 3D Printing

Collaboration

Manual Entry – Worker UI


+++ CONTINUOUS INNOVATION +++


Innovation strategy

** Planned Innovation not yet available, subject to change

Includes SAP Manufacturing Execution,

SAP Manufacturing Intelligence and

Integration, and SAP Plant Connectivity

SAP Distributed

Manufacturing **

(Cloud)


Insights ** (Cloud)

SAP S/HANA Manufacturing Engineering **

Manufacturing Planning

Side-by-side with

S/4HANA innovations

Rapid innovation through

side-by-side extensions

in the cloud

SAP MANUFACTURING

EXECUTION SUITE (On-premise)

SAP MII SAP ME SAP PCo

SAP MANUFACTURING

EXECUTION SUITE (On-premise)

SAP MII SAP ME SAP PCo



Solution Overview

SAP Manufacturing Integration & Intelligence (SAP MII):

Strategic platform for interoperability, integration and intelligence, bringing operational data into business context for IT / OT convergence with pre-defined content for

scenarios, reporting and analytics and dashboards

SAP Manufacturing Execution (SAP ME)

Complete shop floor execution system for discrete manufacturers

• ERP Integration “out of the box” (SAPMEINT)

• Tracking & Tracing on SFC / Serial Number

• Non-conformance Handling

• Interlocking

• Production data acquisition

• Extensibility

SAP Plant Connectivity

SAP ERP (ECC or S/4HANA)

Top Floor

All Industries

All Industries

Discrete Industries

All Industries

SAP MES Solution Recommendations:

Any Industry: SAP MII, SAP PCo

Discrete Industries: SAP ME, SAP MII, SAP PCo

A&D: Complex Assembly Manufacturing

Machine EntryProduction Operator (POD) Shop floor worker UI


SAP Manufacturing Execution

Main Differentiators

SAP Manufacturing Execution – What is it?

• Shop Floor Execution System for the discrete industries

Main Differentiators• ERP Integration “out of the box” (ECC & S/4HANA)

• Controls production of every single unit (lot size 1)

• Easy interaction with shop-floor automation layer

• Unit level Tracking & Tracing / Genealogy

What operation, tool or machine was used, where parts came from, etc.

• Comprehensive non-conformance management including in-line sampling

and ability for visual test and repair

• Process Interlocking

• High flexibility and extensibility; pure SOA based architecture

• High usability with browser-based user interface

• Role-specific access and personalized dashboards for operators

• Flexible production process modeling without additional programming

• Supports HANA

• Active community of partners and customers


DESIGN PLAN RESPOND PRODUCE DELIVER OPERATE

ERP

MES(ME & MII)

PCo

PLC(Machine)

MONITOR

SAP Connected Manufacturing ArchitectureThe Connected Plant in the Extended Supply Chain

» Sensor detects material carrier

» Requests control parameters from ME

» Production plan

» Bill of materials (BoM)

» variant management

» production steps

» Production details management

» Detailed and flexible

» production step routing

» Shop floor controls for each step

» Mapping of ME production details

to PLC control parameters (recipe)

» Serial Numbers

» Quality results per lot

» Order confirmation

» Inventory update, Equipment usage

» Log parametric data

» tolerance checks

» Return „conformance“ or „non-conformance“ decisions

» Mapping of ME production details to PLC control

parameters (recipe)

» Machine reports completion and requests next operation

Co

nn

ecto

rs


SAP Manufacturing Integration and Intelligence


SAP Manufacturing Integration and Intelligence – What is it?

– Extensible manufacturing platform allowing rapid adaption to any manufacturing

process

Main Differentiators• Integration: Provide interoperability (in)between shop floor solutions and enterprise

ERP (PP, PM, MM, QM)

• Intelligence: Visualize data and include KPIs from any of above sources

Provides simple and efficient local user interface and dashboards

• Innovation: Powerful SOA-enabled business logic to enable customer- specific

processes for planning, execution, maintenance and quality

• Allows fast prototyping to achieve fast ROI

• Broad and extensive partner network

• Applicable to all manufacturing industries and utilities


Manufacturing Performance ManagementAt Corporate, Facility, Production and Asset Level

» Analyze Performance Management KPIs

at any time and any organizational level

» Benchmark performance internally and

externally

» Manage by exceptions with thresholds

and alerts

» Browser based reporting that works on

both PC & Mobile devices


SAP Overall Equipment Effectiveness (OEE)KPI Management with Pre-Built Business Process Execution

Real-Time Dashboard – Orders View

Solution Highlights

»Single, common framework

for all plants

»Enterprise wide repository

of operational data

»Cross plant performance

comparison

»Combined with business

context

»Broader business implications

of performance loss

»Framework for performance

capability and production

improvement


Provide real time visibility to energy consumption across the enterprise - Insight To Action – energy, fuel,

steam and water use is optimized in line with production schedules and energy contracts.

Plant A Plant B Plant C

Shop

Floor

Top

Floor

SAP

ERP

SAP MII

on HANA

Performance

Traditional DB

SAP Energy Monitoring & AnalyticsEnterprise Operations Management


SAP Plant Connectivity


SAP Plant Connectivity – What is it?

Communication gateway and interface allowing for shop floor

integration to MES and ERP systems

Basis for Industry 4.0 communication patterns: Notifications /

Queries / Bidirectional data exchange


• Shop floor data can be shown in near real-time on user interface using Web

Socket Server technology

• Mass data upload into SAP HANA

• Integration with SAP ERP* / SAP HANA smart data streaming

• Flexible Web Service Orchestration (RESTful*, ODATA, SOAP*)

• High performance connectivity

• Bundling and buffering of data; notification delivery retry

• Remote Configuration of SAP Plant Connectivity centrally from SAP MII

• Customer specific enhancements possible

(proprietary protocols and complex processing logic)


• Quick Create

• Guided Procedure

• Enhanced Views

SAP QIM – A Comprehensive Approach Elements at a Glance

Object references to

other systems

ERP (…)ERP

ERP (…)

Predefined Object Categories

Quality & Service Notifications

Claims, FMEA Defects, Audit

Questions, and so on

ERP

Context-related

analytics

Creating and

Processing Issues Monitoring, Coordinating,

and Analyzing Issues


SAP Global Batch Traceability (GBT) at a glance

SAP Global Batch Traceability

is like a cockpit across your

global batch genealogy and its

distribution

Search your global batch usage

Explore your global batch usage

Instantly report on your global batch

usage

Key Features

• Capture & link batch usage

across distributed systems to

support GMP

• Graphically explore/

investigate the batch issue

• Fast Reporting to drive

precision recall, withdrawal or

hold

• Pro-active monitoring of your

global batch usage &

distribution

SAP Digital Manufacturing InsightsUnlocking the Benefits with Insights into Digital Manufacturing


DMI- Role based Insights to enable Intelligent Decisions

CxO

Plant & Unit Heads

Supervisors

Setup manufacturing KPI Governance in line with Corporate

objectives

Review and benchmark Revenue, Cost, Delivery Performance,

Quality & Customer satisfaction across manufacturing plants

Expedited decisions

Monitor and Analyze Manufacturing Performance

Indicators

Improved adherence to production schedule

through real time production insights and

expedited actions

Continuous improvement of Yield/Through put,

product Quality, Vendor Quality through

advanced analytics(Predictive, Statistical Process

Control etc)

Advanced algorithm based

insights pointing to causes

Analyze & review prioritized

causes and their impact and

initiate corrective actions

Key Performance Indicators

Manufacturing Performance Indicators

Manufacturing Activity Indicators

ProductivityQuality Cost Delivery Safety


(1) Plant Manager Cockpit displays plant specific performance metrics with current status of the plant.

(2) The KPI trend chart also forecasts and plots the possible trajectory.

(3) He notices that the Defects per Unit is 21,which is above the threshold, with a range of 10 – 15 units for the current year.

(4) The KPI trend helps him understand the distribution of the Defects per Unit over the year against the threshold.

(5) From the trend line forecast, he notices that if the issue is not addressed, it will significantly affect the quality.

(6) The Heat map on the right side of the screen, depicts the line level DPU.

(7) The right bottom section displays contributing causes for the selected Line.

(8) Similar views will be available for all the KPIs in the carousel.

2

47


SAP Digital Manufacturing InsightsSystem Landscape


ERP / S4 HANA

Plant - 1

Quality Cost Delivery Productivity Safety

SAP Digital Manufacturing Insights


Plant - 2

Manufacturing Execution

Plant - x

SAP Distributed ManufacturingCollaborative 3D Printing


SAP Distributed Manufacturing

SAP Distributed

Manufacturing


SAP Distributed Manufacturing: Design Collaboration to Optimize Part Design

for 3D Printing

Design Collaboration

• Allows both parties to collaborate on lightweight

VDS viewing file (CAD original automatically

converted when uploading) – no need to send

large CAD originals back and forth

• Possibility to chat based on embedded screen-

shots

• Design can be approved, added to part and

converted into STL file

Manufacturer Connected 3D Print

Service Provider

Provides CAD Design (

converted when uploading into

VDS viewing file)

Clarifies his questions on

design and Manufacturer can

provide updated Design File

Manufacturer

Approves Design and converts

CAD file into printable STL File

(added to collaboration)

Version 2.0

SAP Model Company for

Digital Manufacturing


The Model Company for Connected Manufacturing is based on standard

solution capabilities provided by S/4HANA and SAP Manufacturing

Executions

Deliver integrated master data framework as a backbone and enabler of the

processes, which will be run in different business areas

Providing demo script to run the complete scenario from customer order,

through production until finished goods is send to the customer including

invoice.

Material

Requirements

Planning

Basic Production

Execution

(S/4Hana)

Repetitive

Manufacturing

Basic Warehouse

Management

Traceability of

individual Shop

Floor Control units

Core Concepts

Production

Planning

Production

Orchestration

Inventory and Basic

Warehouse

ManagementShop floor Execution

SAP Model Company for Connected ManufacturingCore Concepts

WIP Management

Non-conformance

ManagementNon-conformance

Management

Data CollectionMachine

Integration


Thank you.

Contact information:

Fatih Kayadelen

Senior Sales Executive

[email protected]

+90 533 762 39 35

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