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Manufacturing Excellence in Batch Manufacturing Industries

SAP MII Batch Manufacturing

Manoj Narang, Industry Business Unit, Chemicals SAP Labs India Pvt. Ltd. Satya Narayan Sahu, Solution Management, Manufacturing SAP Labs India Pvt. Ltd.

Agenda

1. SAP MII Overview 2. SAP MII for Batch Manufacturing

What is SAP MII?

SAP NETWEAVER

Other SAP Bus. Solu tions Manufacturing Intelligence Dashboards

SAP NetWeaver BI

SAP MII is a plant centric platform that delivers:

Manufacturing intelligence: Real-time analytics engine that aggregates and delivers unified visualization of events, alerts, KPIs, and decision support for production personnel through role-based dashboards

SAP Manufacturing in SAP ERP

SAP MII Manufacturing Intelligence Manufacturing Integration

Manufacturing integration: A single layer enabling SAP ERP connectivity with real-time plant-floor applications (MES, SFAC, and legacy applications) to drive plant-to-enterprise business process interoperability

MES ­ Manufacturing Execution Systems SFAC ­ Shop Floor Automation and Control

Typical SAP MII Application Areas

Adaptive Manufacturing

Manufacturing Operations

SAP Manufacturing (SAP ERP)

Plant-to-ERP Plant-to-Plant

SAP MII

Manufacturing Synchronization Data Integration Work Process Management UI Simplification

Performance Management Dashboards Scorecards Analytics

Manufacturing Integration

Manufacturing Intelligence

Mobile ­ Plant Visibility

SAP and Partners Application on SAP MII

SAP Delivered Application:

http://www.sdn.sap.com/irj/scn/manufacturing-tools

Plant to SAP PP Plant to SAP QM Plant to SAP MM Plant to SAP PM ... Partner Delivered Application as a part of their service offering

IBM: xLC ­ LIMS Connect Trebing & Himstedt: EWI (Electronic Work Instructions), xOEE (Overall Equipment Effectiveness) Invensys/Wonderware: Real Time Finance (RTF), Production Execution Tata Consultancy Services: Rapid Sigma, Online Root Cause Analysis, Flexible KPI Monitoring, Simplified Plant Maintenance, Synchronization of Shop-floor with Planning, Energy Management, Product Mix Determination Ciber Novasoft: Vertical Integration, Batch Monitor, Downtime Analyses, Preventive Maintenance SEAL: Mobile Inspections, Plant Operational Data Store (PODS), Order-To-Ship Dashbord (OTS), Enterprise Desktop Notifications (EDN)

Touch Screen - Plant Data Collection End-to-End Quality Control ...A number of sample plant templates

Benefits - SAP MII as YOUR Manufacturing Platform

Low Cost & Effort

Easy extension of SAP MII infrastructure for manufacturing execution(Lite-MES) Accelerated implementation with out-of-the-box, preconfigured templates Full template and installation documentation for easy implementation and user training

SAP MII Applications

Low TCO

Lean, "Smart" MES approach / application coverage Central data maintenance (no duplication) Seamless integration with SAP ERP and shop floor systems

Low Risk

Proven and scalable "shopfloor platform" Best practice processes

Agenda

1. SAP MII Overview 2. SAP MII for Batch Manufacturing

2.1. Background and motivation 2.2. Brief overview and solution scope

Project Overall Goal & Strategy

Expand SAP Manufacturing with a PLANT-SPECIFIC SOLUTION

Provide A DECOUPLED SOLUTION for MANUFACTURING OPERATIONS

Manufacturing Enterprise Processes Coordination

Manufacturing Operations

Visibility & Execution

Connectivity, SCADA, HMI Automation Shop Floor Process Control

STRATEGY

Extend SAP MII tools with Best Practice templates for shop floor processes, content & user interfaces To meet plant needs for a decoupled, plant-specific solution for manufacturing operations To drive competitive advantage through integrated manufacturing enterprise + operations processes

Customer Needs for Manufacturing Systems

Independent System

Decoupled from ERP enterprise coordination processes With lower implementation and maintenance effort

System Flexibility

Separate upgrade cycles Support of plant-specific processes

System Availability

24 * 7 * 365

Simple, role-specific processes & user interfaces

For plant supervisor and operator

Source: SAP Customer Survey 2007

Central data storage

Data maintenance in ERP > No duplication of data Integration with enterprise and automation systems

Agenda

1. SAP MII Overview 2. SAP MII for Batch Manufacturing

2.1. Background and motivation 2.2. Brief overview and solution scope

SAP Manufacturing Overview

Costing Employee health & safety

Production Asset Management Support

Manufacturing Scope

Quality & Compliance Energy & Environmental Management

Manufacturing Intelligence

Manufacturing Planning Local Logistics Product Data Management

Product Innovation

Scheduling & Sequencing

Work Production Production Instructions Execution Confirmation Execution Production Data Collection

Manufacturing

Manufacturing Collaboration Production Infrastructure Manufacturing Infrastructure

Process simulation

Deliver to customer

MRP & Production OrderMgmt

Supply Chain & Manufacturing Planning

Resource Planning

Service & Repair

Local Logistics

Exception Management

SAP MII Batch Manufacturing Complements SAP Manufacturing

Costing Employee health & safety

Production Asset Management Support

SAP MII Batch Manufacturing

Real-time Manufacturing Analytics and Intelligence (for Supervisor) Manufacturing Execution (for Operator)

Quality & Compliance Energy & Environmental Management

Manufacturing Intelligence

Local Logistics Manufacturing Planning Scheduling & Sequencing Work Production Production Instructions Execution Confirmation Execution Production Data Collection

Manufacturing

Manufacturing Collaboration Production Infrastructure Manufacturing Infrastructure

Process simulation

Deliver to customer

MRP & Production OrderMgmt

Supply Chain & Manufacturing Planning

Resource Planning

Service & Repair

Exception Management

Local Logistics

Product Data Management

Product Innovation

SAP MII Batch Manufacturing Scope Phase 1 Delivery

Manufacturing Enterprise Processes

SAP Business Suite

(SCM, PP, PP-PI, IM/WM, QM...)

SAP MII Batch Manufacturing

Manufacturing Operations Cockpit

Manufacturing Operations

Work Preparation

Manufacturing Order List Material Identification

Work Execution

Electronic Work Instructions Quality Control Production Confirmation

Documentation

Shift Book Monitoring & Logging

Performance

Production KPIs Production Report

Automation

Shop Floor Systems

Inspection/ Equipment Testing LIMS Plant Historian HMI PLC SCADA / DCS Weigh Scales

Manufacturing Operations Cockpit

Preconfigured, user-specific cockpits support efficient plant operations with real-time insight into activities and KPIs, as well as quick access to applications and data Predefined Roles

Production supervisor Shift supervisor Shop floor operator

Role-specific Cockpit Content

Navigation tree Links to applications Canvas Area Central application Example: Operator Cockpit (N.B. No alerts in project phase 1 delivery) (i.e. order list, shift book) Important Key Performance Indicators (i.e. yield, machine performance) with drill down capabilities Links to websites (i.e. MSDS Database)

Manufacturing Order List

User-friendly work list of scheduled process orders and important order details to provide the overview at a glance and support efficient order selection and processing

SAP Business Suite (PP, PP-PI)

Process orders Control recipes

SAP MII Batch Manufacturing ­ Manufacturing Order List Process Order Overview List / Selection Screen

Process order number Plant Material number (of material to be manufactured) Material short text Scheduled start date Scheduled end date Resource Process order status

Example of a similar Production Order List

Follow-up activities

Material identification Execution of Electronic Work Instructions

Material Identification

Automated, handheld and barcode-supported material identification with completeness/correctness checking

SAP Business Suite (PP, PP-PI)

Process messages Process orders (with material list)

(User, date/time, scanned data, & process order for Electronic Batch Record)

SAP MII Batch Manufacturing - Material Identification

Display Manufacturing Order List

Process Order List

Select Process Order

Display Material List Material List Info.

Process order number System Check Material number Material short text Identification status Batch number Reservation number Quantity Unit of Measure

Scan Barcodes & Check Material Correctness Scanned Bar Code Info.

Material number Batch number (Reservation number) (Process order number)

Confirm & Post Results

Complete material identification Cancel material identification

Electronic Work Instructions

Electronic work instructions integrate manufacturing enterprise, operations and device data to provide comprehensive task and process control and documentation

Manufacturing Enterprise Processes

SAP Business Suite (PP, PP-PI, QM)

Process orders Control recipes Inspection lots Process messages

(for Electronic Batch Record, process order, goods issue/receipt, order settlement)

SAP MII Batch Mfg.

Manufacturing Operations

Safety instructions

Display of text, documents, hazard symbols, MSDS

Material identification

Support of manual, visual, barcode identification

Electronic Work Instructions

Electronic Work Instructions

Work instructions

Work instructions and data entry with automatic data validation (manual & automated data entry - process parameters, confirmations, device readings)

In-process quality control

Inspection result recording

Process order confirmation

> All with digital signature and message support

Automation

Shop Floor Systems

Example Electronic Work Instruction Sheet

Process & Data Flow

Process Data PI Sheet

SAP PP SAPEntry of PP, QM

Confirmations

SAP QM

Confirmations

IDOC IDOC

Order Queue Order List Process Order Selection Work Instruction

Inspection feature

RFC RFC

Confirmations, Quality Data

XML // SQL XML SQL

Automatic Confirmations

MI I

Manual input Electronic Signature

Electronic Work Instructions

Quality Control

Convenient application for shop floor quality control, integrating SAP ERP Quality Management, LIMS and device data for efficient result recording and analysis

Manufacturing Enterprise Processes

SAP Business Suite (Quality Management)

Inspection lot Inspection data Batch number Inspection points Physical samples Quality notifications

(Usage decision)

SAP MII Batch Manufacturing ­ Quality Control

Quality analysis

Support of single lot & cross-lot analysis Statistical Process Control (SPC) Manufacturing Operations

Inspection result and defect recording

Manual entry & data integration from LIMS / devices Quantitative & qualitative result types Automatic tolerance validation Defect code notifications Digital signature

Generation of new inspection points and physical samples

Automation

Inspection/ Equipment Testing LIMS Plant Historian HMI PLC SCADA / DCS Weigh Scales

Production Confirmation

A straight forward application for production confirmation of process orders with automatic plausibility and tolerance checking

SAP Business Suite

(PP, PP-PI, MM)

Confirmation data Process order data

(for process order, goods issue/receipt)

SAP MII Batch Mfg

Production Confirmation

(Based on process order header For processing without Electronic Work Instructions)

Start / end date & times Actual quantities for consumed & produced materials

(with automatic system checking)

Partial / final confirmation Batch number Comments (i.e. for exceptions)

Example: Production Confirmation

Shift Book

Easy-to-use shift book applications support accurate shift set-up, as well as comprehensive management and reporting of shift activities, information, and events Shift Master Data Maintenance

To set-up shift structure

­

Factories, shift workers, start date, messages

Shift Instructions

To provide shift-relevant instructions and information to shop floor operators Tasks, due date and times

Shift Notes

To document important production messages and events

Shift Hand-over Report

To summarize production status & shift activities Current production, resource and order status Shift messages and instructions

Shift Book

Examples of Hand-over Report & Shift Notes

Manufacturing Performance

Comprehensive reporting and key performance indicator (KPI) tracking to support timely problem detection and efficient root-cause analysis KPI Watch List

Role-based KPI views (Production supervisor, shift supervisor, operator) Predefined calculations and data points Plant on-time delivery, production plan adherance Production performance, quality throughput, etc. Energy used, energy cost and intensity Flexible KPI selection (time-frame, resource, cost center) Traffic light status reporting Drill down capabilities List and graphical display (line, bar, gauge charts)

Production Report

Production summary and process order list

Manufacturing Performance KPIs

Preconfigured KPI calculations and ERP / PCS interface points

Plant On-time Delivery: # of production orders completed on time / # of completed prod. orders Production Plan Adherance: Variance planned and actual quantities Capacity Utilization: Production unit busy time / Total available time Overall Equipment Effectiveness (OEE): Availability x Performance x Quality Availability: Operating time / planned production time Performance: Actual cycle time / planned cycle time Quality: Good product quantity / produced quantity Throughput: Produced quantity / throughput time Manufacturing Cycle Efficiency: Production time / busy time Energy Used: For all types of energy: Sum of amount energy used Energy Cost: For all types of energy: Sum of amount energy used x unit cost of energy Energy Intensity: Quantity energy used for output / amount of output

All Templates will have a Consistent Style

Styleguide UI Mockups

Key Take Aways

SAP MII for Batch Manufacturing:

A significant area of SAP's Manufacturing strategy An integral part of SAP's Perfect Plant offering Builds on the manufacturing & MII knowledge and expertise of SAP, customers and partners Rounds out SAP's manufacturing portfolio to offer integrated manufacturing enterprise + operations processes Meets customers needs for a decoupled, plant-specific, yet integrated solution Enables SAP to become a serious player in the plant space First phase template delivery Q4 2009

Technical Requirements for SAP MII Batch Manufacturing Implementation

SOFTWARE

SAP ERP: Release > R/3 4.7 Manufacturing set-up: ­ Production Planning ­ Process Industries (PP-PI), ­ Quality management (QM) ­ Materials Management (MM) ­ Plant Maintenance (PM) SAP MII: Upgrade to Release 12.1 SAP NetWeaver Composition Environment (NW CE): Release 7.1 ­ With full content mgmt, life-cycle mgmt Standard database for SAP NetWeaver

HARDWARE

Minimum 4 GB; recommended 8GB for productive system (= standard SAP MII requirements)

OPERATING SYSTEM

64 Bit Windows Server

DATABASE For Best Practice Processes

Microsoft SQL 2005 (for first release only - thereafter support of multiple databases)

Software Costs Involved / Pricing

SAP MII Batch Manufacturing

Free of Charge Downloadable from SAP Service Marketplace Available for all customers with a software license for SAP MII Available for all partners with a demo license for SAP MII

SAP MII

According to latest standard SAP Price List

SAP ERP

According to latest standard SAP Professional User Price List

SAP MII ­ Sample Customers Presented Success Stories at Events

Value from SAP MII in Chemicals

Global rollout ­ improves customer responsiveness, and enhances continuous improvement Savings of $10 million in first year due to improved supply chain processes and visibility; implemented in 120 days Performance Management applications deliver payback in production increases, better margins and reduced energy use Production and Quality KPIs are center piece of executive dashboards; plant to enterprise transactions increase efficiency Energy management apps deliver high value savings, while increasing sales through real time customer commitments

Thank you!

Copyright 2009 SAP AG All Rights Reserved

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