RETHINKING MANUFACTURING IN THE AGE OF MAKERS

Dr. Asuman Sünbül

Rising Challenging Demand for Manufacturers To Produce: Faster, Cheaper and Better

Today’s manufacturing is all about automation using AI, robotics, IoT

We automate in order to run faster, safer, cheaper.

In the business world, to be able to deliver this vision, one needs to

understand the business logic, the processes and workflows. This

knowledge resides in ERP /BPM.

Robots are not standalone entities, they live in a contextual world.

In the business world, that world typically involves BPM/ERP

How to connect to the business world? If each robot acts/performs

the task by its own, e.g. without coordination, this might cause and

has caused troubles to the business.

Today’s Manufacturing

Innovation & Today’s Manufacturing 1.Startups World!!!

Innovation

Strong Foundation Domain Knowledge & Production Suite

Seamless Architecture/ Connecting Top Floor to Shop Floor

flexible production

Robots and machines orchestration

Dynamic routing

Embedded AI technology in production + testing

Automation is pivotal in the smart factory of the future.

As such, Industrial Automation is going to be more vital than ever

before.

Advantage of the limitless business opportunities

SAP is supporting since 40 years customers in the manufacturing

and logistics space

Connecting Top Floor to Shop Floor

Manufacturing Processes

What are the involved processes?

What kind of tasks do robots perform in manufacturing?

What is manufacturing?

Manufacturing Process

A sequence of operations and

processes designed to create a

specific product. The process of

turning materials into a product

Can you think of any manufactured product that consists only from one part?

Domain Knowledge:

casting and foundry

forming: warming and metalworking

Typical assembly processes include mechanical fasting, shouldering and brazing, welding, adhesive bonding:

Rolling material Forging materials

machining

Production

Planning Process Optimization: where are these processes?

All over the place; hidden!

Process Control Transparency

Related information for decision making is scattered throughout different components, like in real life examples

Manufacturing

SAP MII

Variant Configuration

SAP ME

PP

Selection of options

Define Motorcycle

IPPE

Defines Bill of Material, Routings, Operations

Scheduling

Integration to ECC

Performance Management

Manufacturing Execution

Work Flow Enforcement

Automated / Guided Procedures

Plant Connectivity

Integration to Machines

PLM CRM

SD

SCM

PM

Maintenance

Work Order Management

Tool Management

Customer Management

SAP MII

APO

Optimization

SAP Manufacturing ERP SAP ME/MII

SAP EWM

Tracking/Tracing (Casing)

Process Control / Logging

Production Execution

Production Planning Master Data Product Cost cal.

Material Sorting Put to storage Replenishment

Planned Orders

Master Data

Material Sorting Request

Replenishment Request Inventory Counting WHS Management

Mas

ter

Dat

a

Inve

nto

ry

Packing

Reporting (e.g. OEE)

Machine integration (PCo)

Product Routing

Fork lift control Mobile device FEFO

Production FC Raw Mat. Calc. Demand Planning

Business Logic

Non Conformance Mgt.

Article determination

Matrix Production Scenario

Production Visualization

Variant Configuration

Order

Planning

Smart Logistic

SAP S4

MII

ME/PCo EWM

Hybrs

Smart Production

Edge Computing

Highlights:

E2E business process integration from top to shop floor

Completed shop floor management from logistic to production execution for mass customized products

Matrix layout in shop floor for flexible production

Robots and machines orchestration on customized production

Scheduling Optimization on AGVs and robots by edge computing

Dynamic routing based on machine status though IoT technology

Embedded AI technology in production on testing

Business Model, Change Customer satisfaction

Competitive advantage

Higher profit

• Smart Manufacturing Real time insights on machine and environment

• Improved Efficiency Risk, through 3-D visualization of work instructions and change orders

• Re-imagined Products Extend the solution portfolio to enable configuration for smart manufacturing

Mission

Manual assembly: Picking of Components

Assembly

Delivery

QA (two-man rule)

Lot size 1 450 orders per

day

90 % customer-specified

Configurations ISO-9000

Goals and Solution

o Error Reduction

o Quality Improvement

o Show right working

instruction at the right time

o Reduce Manual work

o Always up to date

documents

Introduction of Robots & Automation

Manual assembly:

Picking of Components

Assembly

Delivery

QA (two-man rule)

Lot size 1 450 orders per

day

90 % customer-specified

Configurations

ISO-9000

Handover SAP ERP SAP ME

Assembly according to electronic instructions

Quality Check Confirmation

Label Printing Packaging Traceability

Increased process stability by electronic worker guidance: Always correct instructions and BOMs Always up to date instructions

Increased speed of assembly: Confirmation right at the workplace

Increased process stability by electronic worker guidance: Improved quality through reduced assembly error Traceability

Faster response time of shop floor (e.g. to logistics)

• Everything is connected with everything else • The world is not divided into robotics world, business world, IoT world • The impact and real value lies in connecting end-to-end businesses and

creating full automation: to make it faster and cheaper • Discover how to get more efficient with the business processes • Discover how to grow the robotics business with ERP & manufacturing suite • 90% of organizations believe their customers “value” or “strongly value” is in

personalized products [SCM Magazine] Variant Configuration & Ad hoc configuration of matrix production

• This helps to create real value out of robotics & automation!

Conclusion

Thank you.

Dr. Asuman Suenbuel Sr. Director, Business Innovation with Start ups SAP IoT Start up Accelerator Products & Innovation, BU IoT & Digital Supply Chain Follow us on Twitter: IoT_Accelerator, YouTube: SAP IoT Startup Accelerator and www.sap.com/iot-startup

SAP Labs, Palo Alto

3412 Hillview Ave

Palo Alto, CA 94304

+1 650 4402180 alsuman.suenbuel@sap.com www.sap.com/iot-startup

Fabulous opportunity to create end-to-end apps by combining & discovering new business models in

Robotics & ERP Asuman.Suenbuel@sap.com LinkedIn: Asuman Suenbuel Twitter: asuman