Manufacturing Analytics SAP xMIIfm.sap.com/pdf/8182/11_Cloughley.pdf · SAP AG 2003, Title of...

Manufacturing Analytics SAP xMII

Stephen Cloughley SAP Labs LLC

SAP AG 2003, Title of Presentation, Speaker Name / 2

SAP xMII Analytics overview

�General analytics capabilities

�SAP xMII analytical capabilities

�SAP xMII analytics applications

� root-cause analysis

� 6-sigma (Define Measure Analyze Control)

� Process Analytical Technology (PAT)


SAP Analytics | architecture & system requirements

LegacySystem

LegacySystem

3rdParty

3rdParty

SAPBI

SAPBI

SAPCRM

SAPCRM

SAPPartner

SAPPartner

SAPERP

SAPERP

SAP Analytics

SAP NetWeaver

Composition Platform

BI, BI Kit, Visual Composer, Portal

Partner, ISV

� Adobe Flash Player (v7.0+)

� Netweaver 2004s SPS7

�ERP2005

�EP 7.0 and/or EP 6.0 (EP

6.0 supported for Runtime

only (a separate EP 7.0

development instance is

needed)

� BI7.0 and/or BI 3.5 (BW 3.5

SPS14 supported)

� VC 7.0 (BI Kit part of VC

installation)

� Backend Systems depending

on xApp.

Not focused on charting or spcNot a plant-level deployment


How to create SAP Analytics

Quad View Hierarchical View

Static Atomic Chart

Static Composite(related, but not

interactive)

Dynamic Composite(related and interactive)

Table ��(Chart + Form)

Chart +Table

Visual Composer Designtime

Locate your data service and

design the iView logic.

1111 2222

44443333

Pick a ‘Floor Plan” and define your

application needsConfigure Component Patterns and

Chart Types

Adjust Layout Appropriately - deploy

and check the model in runtime.


Runtime & Designtime


SAP Analytics: Best Practice Scorecarding

Features & Value

� Seamlessly integrated with the Strategic

Enterprise Management (SEM)

application of mySAP ERP. The

scorecards set up in SEM are visible in

composite application

� Any data change (status, assessment

etc.) performed is saved and tracked

within the SEM back-end system.

Business Problem

� To support strategic management and performance measurement processes, the Best Practice Scorecarding

analytic composite application enables a manager to get an instant overview of the basic elements of a

balanced scorecard he or she is responsible for (incl. objectives, measures). It displays the elements’ meta

data incl. long-text definitions and measure formulas, as well as the time series of any value fields (e.g. actual,

plan) defined at the measure level. The manager can enter qualitative assessments on his or her objectives or

measures or override the system-generated status (red / yellow / green) for these elements manually.

Technology / Architecture


� EP 7.0

� EP 6.0 supported for Runtime only (separate

EP 7.0 development instance is needed).

� mySAP ERP 2005 FINBASIS 600 SP06 + notes

976360, 975688

� VC 7.0 incl. BI Kit part.

Manager (Scorecard Responsible)

Review objective and

measure statusView objective or measure

detailsOverride status manually if

needed

Provide textual

assessment


SAP Analytics: Investment Approval

Features & Value

� Single point of entry for investment

approval with all required information.

� Actionable Application enabling user

productivity the immediate processing of

appropriation requests.

� New user experience in the area of

Investment Management.

Business Problem

Appropriation Request Approval (mySAP ERP – Investment Management).

ERP Functionality with multiple transactions to get information.

Limited Web functionalities.

Complex user interface.

Technology / Architecture


� EP 7.0

� EP 6.0 supported for Runtime only (separate

EP 7.0 development instance is needed).

� mySAP ERP 2005 SP 04

� VC 7.0 incl. BI Kit part.

Investment Requester

Investment Approver (Manager or Business Analyst)

Get Appropriation Requests to be approved

Get the appropriation request’s details and

values

RejectAppr. Request

Send backAppr. Request

to Requester

ApproveAppr. Request

Get the related Investment

Program values.


High-tech

SCM Forecast Analytics

Service Performance Analytics

Service Profit Analytics

NPDI Projects Analytics

Automotive

ICH Alert Monitoring: SMI Supervisor at Customer

ICH Alert Monitoring: RP Supervisor at Customer

ICH Alert Monitoring: PO Supervisor at Customer

EC&O

Facility Operations - Damage Analytics

A&D

Pilot Report

IM&C

Service Manager

VP of Sales

NPDI - Product Line Manager

Demand Overview

SCM

Global Capacity Utilization

Global Inventory View

Order Analytics

Warehouse Stock Analysis

Warehouse Workload Historical View

Responsive Replenishment

Delivery Performance

Demand/Supply Match

Material Availability Analytics

Supplier Rating Monitor

PLM

Projects Dashboard

Quality Dashboard

Take from Stock or Buy Dashboard

NPDI Analytics

SRM

Contract Management

Category Management

Supplier Order Management

Manufacturing (via PP or PP-PI only)

Overall Equipment Effectiveness

OEE Performance

Yield OEE

Availability - OEE

OEE-Yield Scrap

Scrap Quantities Analysis - Plant Level

Capacity Utilization - Plant Level

Inventory Overview

Material Utilization

Material Consumption Value

Quality - Problem Analysis

Production Flexibility

Plan Realization

Manufacturing Order analysis

Material Costing T/A

Production Analysis - Variance

Manufacturing Activity Analysis

EHS

EHS Waste Approvals - Quote ofreleased quantities

EHS Hazardous Substance Inventory

Inventory Overview

SAP® xApp™ Analytics - May 2006 shipment (1/3)

SAP® xApp™ Analytics can be downloaded from SAP Marketplace.


SAP xApp Analytics – Piloting in two Steps

Sept. Sept. ‘‘0606 ~Nov ~Nov ‘‘0606

Phase I

Design Partnering (non productive usage)

Phase I

Design Partnering (non productive usage)

Goals

� Proof Business Value of xApp

� Learn how to deploy and adapt xApps

� Understand the Business use cases for xApps in your organization

Scope

� Implementation of xApp

� Feasibility study & scoping

� Implementation of selected customer extensions

� Validation with Business Owners

Phase II

Pilot implementationfor productive usage

Phase II

Pilot implementationfor productive usage

Goals

� Proof readiness of xApps for productive usage

� Proof value of SAP NetWeaver Composition Capabilities

� Proof Business Value of enterprise SOA

� Create success stories for xApps

Scope

� Implementation of xApp

� Implementation of required customer extensions

� Productive Usage

~May ~May ‘‘0707

ShipmentShipment GoGo--LiveLive RTCRTC


xMII characteristics

xMII is a plant-level solution; not a “single instance” solution

xMII runs on a standard web server platform� http://help.sap.com/saphelp_xmii115/helpdata/en/Getting_Started/InstallationGuide.htm

xMII does not need any other SAP components

Deployment in days/weeks

Skillset: web knowledge, plant floor knowledge, Javascript


� Plant Manager Scenario

Typical data presentationTypical data presentationTypical data presentationTypical data presentation

Connectors

xMIIxMII

S 9 5 O th er

sO pe

n

O & MA n al

yt

ic sA le rt sK P I

Visu

aliza

tion

Web

Serv

ices

Bu

si

ne

ss

Lo

gi

c

Mfg.

IntelligenceMfg. Integration

Data Service Layer

Intelligence Integration


Visualization

Equipment Tracking and Performance

Scrap Reporting

Downtime and OEE Reporting


Analysis tools

An Exponentially Weighted Moving Average (EWMA) chart plots a weighted average of all past and current observations

EWMA

Two charts, an XBAR and a Standard Deviation. A standard deviation chart plots the standard deviation of the characteristic values in the subgroup (Requires a subgroup greater than 1)

XBAR-SDEV

Two charts, an XBAR and a Range. A range chart plots the range of the characteristic values within the subgroup (Requires a subgroup greater than 1)

XBAR-RANGE

Two charts, an XBAR and a Moving Range. A moving range chart plots the difference between the range value for this subgroup and the range value for the previous subgroup. This chart is often used with a subgroup size of one, known as an XBAR-Individual Moving Range.

XBAR-MR

Plots the mean of the characteristic values in the subgroupXBAR

DescriptionChart Type


Analysis tools

Two charts, an EWMA and a Moving Range. See XBAR-RANGE above for further reference.

EWMA-RANGE

Two charts, an EWMA and a Standard Deviation. See XBAR-SDEV above for further reference.

EWMA-SDEV

A Box and Whisker chart is also known as a boxplot. It provides an alternate visual method of evaluating the spread of data for all visible characteristics. It uses the median set of data, the inter-quartile range and the extreme values to describe pictorially its pattern of variation.

BOX-WHISKER

A Histogram chart shows the distribution of a process, plotting the relative frequency of an event within a process versus the possible process outcomes.

HISTOGRAM

Two charts, an EWMA and a Moving Range. See XBAR-RANGE above for further reference.

MEDIAN-RANGE

A median chart plots the median value for the subgroupMEDIAN

DescriptionChart Type (cont’d)

http://help.sap.com/saphelp_xmii115/helpdata/en/Advanced_Topics/Illuminator_Quality_Portal/iSPCChart_Reference.htm


SPC capabilities


SPC - interactivity

When a data point in

the Production Order has a

comment, a ‘RED

FLAG’ will appear over the data point

Outlier Point(s) are

identified with a ‘X’over the data point


SPC – multivariate analysis


Process Analytical Technology

“a system for designing, analyzing, and controlling manufacturing through timely measurements (i.e.,

during processing) of critical quality and performance attributes of raw and in-process materials and

processes with the goal of ensuring final product quality.”

Tools

� Continuous improvement and knowledge management tools

� Multivariate data … analysis tools

� Modern process analyzers or process analytical chemistry tools

� Process and endpoint monitoring and control tools

FDA [http://www.fda.gov/cder/OPS/PAT.htm]


� focus on process improvement, away from rigid SOPs

� quality built-in: measure, feedback, control

� clear picture of every stage in the process

� Show anomalies in real time – “continuous” FDA compliance

� rectification in real time – rework reduced, cycle time reduced

� less waste/scrap, enhanced compliance

value proposition

� KPI visualisation provides the metaphor for process monitoring

� alerting provides automated response processes, including escalation

� Speedy batch disposition

Process Analytical Technology


xMII role

Make Up Processing PackagingRaw

Materials

FinalProduct

On-lineMeasurements

ProcessControl

LabAnalysis

R&DInformation

Multi-factorialAnalysis

Shared Knowledge Management

Over Product LifecycleContinuousImprovement

Customers

DistributionMake Up Processing PackagingRaw

Materials

FinalProduct

On-lineMeasurements

ProcessControl

LabAnalysis

R&DInformation

Multi-factorialAnalysis

Shared Knowledge Management

Over Product LifecycleContinuousImprovementContinuousImprovement

Customers

Distribution

ProcessUnderstanding

JustifyInnovation

Risk Analysis& Mitigation Process

Design

xMII


Validation; ease of implementation

Validation

� Deployed in validation environments

� Does not impact validation status of data sources

� Not a record keeping system

� Life sciences user input – requirements gathering


Manufacturing Challenge: How to 'automate' from Start to Finish ?

PlanPlan

PreparePrepare AnalyzeAnalyze

ReportReport

InstructInstruct

ReleaseRelease

RecordRecord

• Product• Timeframe• Quantity• Plant

• Units• Recipes• Master Batch Record• Training

• Operator Procedures• Checklists

• Values• Checks• Events

• Batch Record• Exceptions

• Cycle Times• Quality• KPI Metrics

• Samples• Pass/Fail• CoA

• Automatic Execution• Machine Parameters• Recipe Execution

OperateOperate

Covered by

Shop-Floor-Systems

SAP

xMII


Further Implementations Interactive checklist for cleaning operations


Further Implementations

Interactive list for checking of batch reports


Global MES Project (Plan)

� Leadership Green Belt Six Sigma Project (VP

Manufacturing)

� Rapidly deploy Lighthammer CMS (now xMII) to all Mfg Sites

� Implement standard set of Manufacturing (Mfg) KPIs and navigation (base system)

� Use Celanese standards where possible:

�Microsoft, SAP, OSI PI

�SQL, Sharepoint portal


MES Views Data Visualization Drives Improvement


MES Views Good Tool for Six Sigma Control Plans


� Facilitate workflows and drive out non-value activity and cost

� The right information at the right time

� Freedom to Innovate

� Leverage common framework and reusable components

� Improving and capitalizing on global workflows

� Empowering the Business – matching the skills, meeting the needs

� “Troops on the ground”

� Not about a tool, its about capitalizing on opportunities

� Going Fast, Taking Risks, and Learning

� Six Sigma – Measure & Control

� Value Chain Network – Customers/Suppliers

� Organizational shift

Information Delivery NWG Philosophycontinued


Composite Application SAP Enterprise Portal


Easy to find applications that ‘I’ need


The report is broken up into Portal iViews which allows eventing to target parts of the page and only refresh that part. (The employee

does not have to wait for the entire page to refresh.)

iViews

Case study - OEE

Consumer Product Industries


LEDS (Line Event Data System)

Functions Being Deployed

• Automated data collection of line events

• Real status of all assets and machines on line

• Graphical user interface for operators to review, edit, and comment on downtime events.

• KPI reporting (Efficiency, MTBF, MTTR, Availability, etc.) by line,

machine, shift, etc.

• Trend charts on key metrics

• Production scheduling function

• Work flow for process improvement functions

• Detailed, ad-hoc, downtime analysis

• Changeover management

• Daily production and management reporting

Overall efficiency increase: 65% �� 85%


Data Collection Performance Charting

Analysis

Drill Down


Thank you

Stephen CloughleySr. DirectorManufacturing Applications

SAP Labs LLC

350 Eagleview Boulevard

Exton, PA 19341, USA

T +1 610 903-8000

E [email protected]

Manufacturing Analytics SAP xMIIfm.sap.com/pdf/8182/11_Cloughley.pdf · SAP AG 2003, Title of...

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