SAP - SAP'NİN YENİ ÜRETİM OTOMASYON YAKLAŞIMI - SAP Forum 2013

Ralf Lehmann | EMEA Center of Excellence Manufacturing, SAP Deutschland AG & Co KG

April 2013

SAP Manufacturing Innovations in the Shop Floor

© 2013 SAP AG. All rights reserved. 3

Manufacturing Video Opener 2013


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The Perfect Plant: Challenges today

VP Manufacturing VP BU

CIO

VP Operations VP Sales

Disconnects

Ensure compliance with internal

and external regulations and

corporate initiatives

Align strategy and execution

through Manufacturing analytics

Maximum process agility with

reduced cost and improved quality

Effectiveness & Efficiency Responsiveness Compliance


SAP Manufacturing Strategy and Vision From perfect orders to perfect plants

Our intention is to minimize disruption caused by any kind of disconnects …

… to increase productivity and efficiency by

- Higher transparency

- Faster Reaction to Changes

- Adequate inventory levels

- Reduced Production Cost

Global Orchestration

From Business Strategy to Production

Visual Manufacturing Engineering

Production Planning and Scheduling

Manufacturing Network Collaboration

After Market Sales & Service

Local Execution

State of the art Plant Execution

Fully integrated Make & Move

Visual Manufacturing with Right

Hemisphere

Real World Integration and Mobility

Man

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g P

erf

orm

an

ce

Man

ag

em

en

t R

ea

l-tim

e a

nd

pre

dic

tive

in

telli

ge

nce u

sin

g H

AN

A

… across the value chains ...


There are multiple options for SAP in the Shop Floor

SAP MII

SAP ERP

SAP PCo

SAP ME

Machine Entry ME POD

SAP MES SAP MII with or without Worker UI*

SAP ERP

SAP MII

Worker UI* Machine Entry

SAP PCo

* Planned shipment in Q2 / 2013

Shop Floor

Enterprise

Range of use

» Manufacturing Execution

System

Target Industries

» Discrete Industries

Highlights

» Tracking & Tracing

on SFC / Serial Number

» Non Conformance Handling

» Interlocking

» Production Data Acq.

» KPIs, Reporting & SPC

» Highly Extensible

Range of use

» Integration & Intelligence

» Reporting & Analytics

» Individual Scenarios and Use

Cases

» Worker UI*

Predefined MII Content for Data

Collection for less complex

scenarios

Target Industries

» All Manufacturing Industries

Highlights

» Highly Extensible


SAP Integrated Manufacturing Solution

Production Planning and Scheduling

Manufacturing Execution

Quality Planning and Control

Performance Visibility and Monitoring

ERP PP

APO PP/DS Shop Floor Dispatching and

Monitoring Tool

MII

ME

ERP QM

ME

QIM

ERP

MII

ME

Dashboards

BOBJ


Manufacturing Solution Portfolio Seamless Integrated Solutions

» Product and process visualization » Product structure synchronization » Process planning

Manufacturing engineering

» EH&S » Energy management

Sustainability and safety

» Asset operations » Asset maintenance

Asset management

» Work order collaboration » Critical data exchange

Outsourced manufacturing

Outsourced

manufacturing

Manufacturing

Integration and

Intelligence

Manufacturing

Execution

Production

Planning Quality

Management

Asset

Management

Sustainability

and Safety

Manufacturing

Engineering

» Marketing and lead management » Dealer business management » Vehicle sales management » Aftersales support and service

Manufacturing Integration

and Intelligence (SAP MII)

» MES for discrete industries » Production control for process industries

Manufacturing execution

» Production planning » Lean manufacturing » Production order management » Detailed scheduling

Production planning

» Quality engineering & planning » Quality inspection » Quality notifications » Quality improvement » Audit management

Quality management

SAP MII SAP Manufacturing Integration and Intelligence

© 2013 SAP AG. All rights reserved.

Trends

» EMI (Enterprise Manufacturing Intelligence)

» Process and system harmonization

» Traceability, process enforcement

» GREEN, Energy Management

Customer Challenges

» Transparency and Interoperability

» Semantic Business Layer

» Sustainable Manufacturing

Energy, Visibility

Corp

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Pla

nt (d

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al)

SF

AC

PLC DCS PLC PLC DCS …

SAP Manufacturing

Ralf Lehmann | EMEA CoE SAP Manufacturing

SAP Manufacturing Whiteboard

Business

Suite BW

Composites Analytics

SCADA DB MES Historian SFD Maint-

enance


Trends

» EMI (Enterprise Manufacturing Intelligence)

» Process and system harmonization

» Traceability, process enforcement

» GREEN, Energy Management

Customer Challenges

» Transparency and Interoperability

» Semantic Business Layer

» Sustainable Manufacturing

Energy, Visibility

Corp

ora

te

Pla

nt (d

ece

ntr

al)

SF

AC

PLC DCS PLC PLC DCS …

Benefits

» Integrated MFG Solution

» Out of the box integration

» Transparency

» Composites

» Operator dashboards

» RDS available

Ralf Lehmann | EMEA CoE SAP Manufacturing

SAP Manufacturing Whiteboard

Business

Suite BW

SCADA DB Historian Maint-

enance

HANA

Customer Success

» Valero, 220 M$ / year

» Caterpillar, ABB

» Coca Cola

» Pepsi Corporation

» Sika: RDS BM

» Phillips, 50% Quality improvement

SAP Manufacturing

Mobile

Intelligence Integration Innovation

SAP ME SFD

SAP MII PCo


SAP MII Product Roadmap 2011-2014 Planned Product Release Timeline

SAP MII 14.0

SAP MII 12.0

SAP MII Planned

Q3 Q1 Q2 Q3 Q4 Q1 Q2 Q4 Q1 Q2 Q3 Q4

2012 2013 2011

Q1 Q2 Q3 Q4

2014

GA RTC

RTC GA

GA RTC

» Self service End User Composition Environment

» MII Facelift with CVOM and UI 5 (new UI5 snippets instead of applets)

» Integration of Plant Information Catalogue with ERP PP, PM

SAP MII (Planned*)

USER EXPER, MULTI-INDUSTRY, SAP TECH, PLATFORM

* Projected release dates and scope are not yet in planning stage therefore is subject to change.


Outlook: SAP MII Self Service Composition Environment For real-time and flexible business intelligence

» Browser Based Design Time for the End User to easily create Dashboards

/ Reports for analysis of various kinds of Manufacturing Data via Drag &

Drop:

» “Real-time”-Information from the shop floor like Pressure, Temperature,

etc. – Using the Plant Information Catalogue

» Data out of other systems like ERP / SCADA / Data Historians etc.

» Flexible Reporting / Dash boarding provides high transparency

» Adapt reporting / dash boards always to the latest needs / bottlenecks

without the need of IT personnel

Planned innovations

Solution Enhancements Key benefits


Outlook: SAP MII on HANA

» High performing In-Memory Analytics for large amount of Data (“Big Data”)

» HANA provides the ability to store a significant and broader selection of

manufacturing data for more thorough analysis and more complex

comparison of data.

» HANA provides various statistical algorithms for deep analysis, clustering

and prediction

» The ability to manage large volumes and multiple types of data provides

ability to develop, train and utilize predictive techniques (e.g., regression

and heuristic) for forward looking analysis.

» New insights into the shop floor based on trends / prediction with HANA

capabilities

» Enables near real time analysis of shop floor data to identify preventive

actions

Planned innovations



Real-time Shop Floor Status


Automated production from finished product to ERP – PP at Femsa Coca-Cola


Automated label print with barcode at Femsa Coca-Cola


Real time tracking of production plan at Femsa Coca-Cola

SAP ME SAP Manufacturing Execution


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ties

SAP Manufacturing Execution Solution Suite Overview

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


Integrated User Interface high volume/low mix, make-to-stock, repetitive manufacturing

■ 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”

■ 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

Key Features and Benefits


SAP ME Routing Enforcement and Process Assurance

■ Ability to create, edit and modify a

manufacturing route

■ Ability to support alternative and sequential

operations, add conditions and logic,

automate actions and nest multiple routes

into a single operation

■ Ability to display route in a graphical or

tabular format

■ Execute build plan and enforce route

enabling process control

■ Graphically model build plan to optimize user

experience

■ Automate actions for shop floor operators

and conditions based on manufacturing

events

■ Reduce errors and improve quality


Alternate Operations

Conditional Routing

Automatic Actions

Routing Logic

Sequential Operations

Nested Routings


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

■ Complete “as built” record in a single report

■ Electronic Device History Report

■ Tree structure for drill down capabilities

■ Ability to retrieve and display data as

needed

■ Direct link to As Built Summary Report

■ Enhanced support to view archived product

genealogy

■ Complete process and component level

traceability

■ Complete genealogy in a single view

■ Maintain customer and regulatory

compliance

■ Rick mitigation for recall exposure

■ Strengthens support for industries mandated

by heavy regulatory compliance


SAP Confidential


Your Choice: Paper vs. E-DHR

E-DHR: Electronic Device History Report


SAP ME Unit Level Traceability

Operators via User Interfaces Machines via Web Services Auto-assembled Components

Whatever way you choose, the component information

is logged and is available at any time via...

SAP ME supports various ways to collect component data


SAP ME Backward Traceability

Tough it may happen that a component is defective. This means that units that contain this component may potentially be defective. All you need

it to quickly find all units that use the component with particular assembly data.

Just select what data

you are looking for

and task the system

to find it for you...

SAP ME Component Usage Report gives you full components to material level visibility


SAP ME Touch Screen POD

» Support for various touch devices including monitors and tablets

» Minimum supported resolution is 1024x768

» Simplified, touch-friendly screen navigation

» Graphical status indicators

» Better readability

» Sound alert upon error display

» Button change when process is complete

» Icon and text on the button

» Ergonomically sized touch buttons and fields

» Slide menus and pagers

» New table layout

» Visibility where the product is in the process


SAP ME Touch Screen POD

3D Models

» Visual Enterprise Viewer (the former Right Hemisphere technology) is now

embedded into the POD as a Work Instruction plug-in

» View 2D/3D models that can be created in the Visual Enterprise suite as a

.RH file format

» Scenarios:

» Assembly

» Visual Test and Repair

HTML Pages

» Viewing of an image or HTML page

in a POD plug-in

» Can be used e.g. to view MII reports

and dashboards within the

context of the ME POD

Planned innovations


» Allows the shop floor operator to have an interactive experience with

2D/3D models w/out having to leave the POD

» Flexibility to provide various kind of content to the operator


SAP Manufacturing Execution „Out-of-the box“ Integration with SAP ERP

» Communication based on Web Services,

BAPI, RFC

» MII for Integration, Extensions and Customizations

» End-to-end Process Integration between SAP ME

and ERP

» Extend-able and customizable scenarios support

Master/Transactional Data Transfer End-to-End Process Integration

SAP OEE SAP Overall Equipment Effectiveness (OEE)


Overall Equipment Efficiency on HANA Architecture Overview

Central repository enables global

visibility with full drill-down

Use of raw data instead of complex

aggregation and synch mechanisms

Real-time execution of complex KPI

calculation algorithms

Direct machine connectivity to collect status

information etc

Data buffering at plant level through

MII/PCo


SAP Overall Equipment Effectiveness (OEE) Real-Time Visibility to Production Performance

» Real-time visibility and monitoring of performance metrics

» Production data combined with business data

» Real-time calculation and presentation of OEE metrics

» Real-time alerts and notification of production issues

» Simple, touch screen user interface

» Add qualitative comments and context

» Connectivity to disparate plant systems and data sources

» Automated, real-time data collection


SAP Overall Equipment Effectiveness (OEE) Enterprise OEE for Broader Supply Chain Improvement

Plant - 2

ECC

Plant - N Plant - 1 Plant - 3

HANA

» Single, common framework for all plants

» Enterprise wide repository of data

» Cross plant performance comparison

» Combined with business context

» Broader business implications of performance loss

» Framework for broader set of performance capability

and improvement


SAP Overall Equipment Effectiveness (OEE) Comprehensive Solution Approach

Configurable

Operator

Dashboard

Centralized

OEE

Configuration

Cross Plant,

Business

Context-

Related

Analytics

Simple Operator UI and Data Entry




OEE Plant UI Record Scheduled Downtime


OEE Plant UI Order Dispatch


OEE Plant UI Real-Time Dashboard – Order Selection


OEE Plant UI Real-Time Dashboard – Monitor Production


OEE Plant UI Real-Time Dashboard – Multiple Orders


OEE Plant UI Real-Time Dashboard – Data Collection


OEE Plant UI Real-Time Dashboard – Review and Confirm Order

SAP SFD&M SAP Shop Floor Dispatcher and Monitoring


New Features in SAP MII 14.0 Performance Management Enhancements

» Overview of planned manufacturing tasks per work center

» Easy and intuitive assignment of manufacturing tasks to machines via

visualization of alternative machines, order and operation dates

» Visualization of production program for individual / all machines

» Monitoring functions such as confirmation progress, status of predecessor

tasks, display of important due dates/times, machine breakdowns,

overload situations, visualization of high-priority orders, alert monitor

» Set of open interfaces/BAdIs

» New, highly interactive UI for production supervisors or supervisors

supporting state-of-the-art UI techniques

» Decision support for order assignment to individual resources

» Quick reaction to unforeseen events

» Standard integration: no need to integrate third-party tools

» Based on available data structures in SAP ERP


New innovations


Dispatching – Overview

Customizable visualization of

order & operation dates

Alert Indicator

Visualization of alternative

machines

Overlapping Production Tasks Wait Time

Detailed

Information


Monitoring – Overview

Visualization of

wait time Refresh Manipulation

of colors

Visualization of

machine events

Confirmation

status Visualization of

non-working time


SAP Shop Floor Dispatching and Monitoring Tool Planned Innovations

» Integration to SAP ME

» Integration to Worker UI

» Inclusion of maintenance orders

In the future support of

» Repetitive Manufacturing

» Process Manufacturing

Faster decision support for users and higher performance


Planned innovations

SAP Mobility


Mobile Demo Screen

MOBILE DEMO

VISIT THE SAP CHANNEL AT : http://www.youtube.com/SAPVideoMOM


SAP Manufacturing in Social Media Follow us and stay tuned

YouTube Channel for Manufacturing

Watch manufacturing customer success references, leanr about intereting topics

and news with the videos shared on the oficial channel from SAP Manufacturing.

Link: http://www.YouTube.com/SAPVideoMOM

Enterprise Manufacuring Operations on Facebook

Wanted to be informed whenever important topics related to manufacturing come

out? Wanted to get latest news in your facebook account? Please join the facebook

page for SAP Manufacturing. Link: http://www.facebook.com/SAPMFG

SAP Manufacturing on Twitter

Interest in receiving manufacturing tweets from SAP? Please join the twitter channel

for SAP Manufacturing and stay tuned. Link: http://www.twitter.com/SAPMFG

Enterprise Management Operations

Connected to LinkedIn? Wanted to get updated and interact with the stakeholders?

Questions to the community of just interested in ongoing discussions? Join us.

http://www.youtube.com/SAPVideoMOM

http://www.youtube.com/SAPVideoMOM

http://www.facebook.com/SAPMFG

http://www.facebook.com/SAPMFG

http://www.twitter.com/SAPMFG

http://www.twitter.com/SAPMFG

http://www.linkedin.com/groups?about=&gid=3756546&trk=anet_ug_grppro

Thank You!

Contact information:

Ralf Lehmann

Center of Excellence EMEA

Line of Business SAP Manufacturing

SAP Deutschland AG & Co. KG

[email protected]

mailto:[email protected]


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