SAP Manufacturing Executionfm.sap.com/data/UPLOAD/files/SAP ME Workshop - Implementation B… ·...

Tim KlimaviczSAP Consulting

March 16, 2010

SAP Manufacturing ExecutionImplementation Best Practices

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SAP Internal &confidential

Implementation PlanningProject scopingDeployment strategyAssembling a winning teamTypical timelinesSystem LandscapeMulti-site architecture considerations

During implementationThe most common shortcutERP integrationMachine integrationArchiving & performanceReporting

Post-implementationPlanning post-production supportRecommendations for ongoing support

SAP ME Implementation Best PracticesTopics

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SAP Internal &confidentialImplementation Best Practices

Project Scoping

General:

What are your objectives?

e.g. process enforcement, quality, traceability, visibility.

How will success be measured at the end of the day?

Manufacturing discussion topics:

Which plant(s) and product(s) are in scope?

Type of manufacturing

Overview of production routing(s)

UI requirements for production operators

Data collection requirements

Traceability and compliance

Labor tracking

Shop floor printing requirements

Display of work instructions

Packing

Engineering Change Order process

RMA

Quality discussion topics:

Rework loops/corrective actions for non-conformances

SPC/SQC requirements

Certifications

Yield data/analysis

Non conformance data

Real-time yield reports

Key performance indicators

IT discussion topics:

System architecture (preferred O/S and database)

System sizing information

Machine interfaces

ECC and other application interface requirements

Reporting strategy & standards

Bar coding, RFID and other input interfaces

Shop floor printing

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Deployment Strategy

Considerations• Which plant or line(s) should you target first?• Master blueprint vs. local blueprinting• Parallel vs. sequential roll-out of sites• Parallel with ERP or sequential• How much functionality• Legacy system conversion

Recommendations• Look for site with good payback that has strong

team and solid sponsorship• Limit scope in initial deployment• Master blueprint allowing for local variations• Single site or line roll-out for early success• Build knowledge and apply lessons learned to

follow-on sites• Take more responsibility to reduce cost and build

ownership• Evaluate value of legacy data conversion vs. cost• ME can run standalone ahead of ERP deployment

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Assembling a Winning Team

Role Commitment

ME Application Consultant Full-time

ME Integration Consultant Part-time

ERP Consultant* Part-time

ME Developer* Part-time

MII Developer* Part-time

Machine Integration Part-time

NetWeaver* Part-time

Project Manager Part/Full-Time

Typical Consulting Roles

* Roles that can potentially be filled by the customer

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Assembling a Winning Team

Role Commitment

Project Lead Full-time

Product / Process Engineer(s) Part-Full Time

Test/Quality Engineer(s) Part-time

Production Control Part-time

Production Manager Part-time

IT Resources Part-time

Executive Sponsor Part-time

Typical Internal Roles

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“Typical” Timelines

- Focused project scope, e.g. shop floorvisibility, enforcement on 1-2 lines

- Manual processes for data collection- Vanilla ERP connector

- SAP ME with robust ERP integration- Enhanced scope, e.g. NC, RMA, labor- Machine integration- MII analytics

- Complex mfg process / enhanced scope- ERP integration with complex scenarios- Highly automated data collection from

several machine types- Robust MII analytics

3-4months

6-9months

9-12+months

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SAP ME System Landscape

NetWeaverInstance

SAP ME

DatabaseInstance

NetWeaverSchema (ME)

APPLICATIONSERVER

NetWeaverInstance

SAP MIISAPMEINT

DatabaseInstance

APPLICATIONSERVER

SAP MEWIP Schema

DATABASESERVER

DatabaseInstance

SAP MEODS Schema

DATABASESERVER

DatabaseInstance

NetWeaverSchema (MII)

SAPMEINTSchema

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High Availability Options

DatabaseInstance


APPLICATIONSERVER

DatabaseInstance

APPLICATIONSERVER


DatabaseInstance

APPLICATIONSERVER


NetWeaverInstance

SAP ME

DatabaseInstance


APPLICATIONSERVER

SAP MIISAPMEINT

NetWeaverInstance

SAP MIISAPMEINTSAP ME

SCS SCS SCSSCS

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Multi-Site Architecture Considerations

Consideration Central Local Comments

Initial investment Duplicating high availability is costly

Operational cost Maximize utilization / cost absorption

Change management Consistent IT policies easier toimplement

Centralized data repository Cross site reporting / moving data

Integration to ERP / other apps Less costly and centrally managed

Optimal performance Depends on type of mfg. and WAN

Downtime risk Standalone operation / localresponse from IT support

Highly automated manufacturing Response time is critical

Remote plants WAN performance and/or reliability

Local control Recommend enforce consistentconfiguration and change control

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The most common shortcut

Plan Build Run

Business Scenarios Test Scripts End to End Flows

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MExMII

ERP

Enterprise

Local or Regional

SAPMEINT

Implementation Best PracticesERP Integration

ResourcesERP expertise from customer side is key

Provide expertise on customerconfiguration

Production Engineering participationTo provide data requirements on orderrelease, production activities and any 3rdparty integration on shop floor

Consulting – ME, MII, SAPMEINT, ERPExact resource mix project dependent

ApproachMap out the end to end process across ERPand MELeverage flexibility of ERP connector

Pre vs. Post MESAlign ERP-MES processes with bestpractices

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Machine integration services 2 primarypurposes

Collect data and/or non-conformance on aparticular operationAutomate the WIP transport to eliminatedirect operator activity and enforce MESrules

RecommendationsIdentify the machines that can provide theneeded dataIdentify what meaningful data and non-conformances are generated by the machineMap to data collection and non-conformancerequirements in Blueprinting phaseDon‘t collect data for the sake of collecting data!Consider the various options and associatedcosts of data acquisition, e.g. availability of acommon interface and vendor-specific software

Implementation Best PracticesMachine Integration

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Archiving & Performance Tuning

WIP archiving must be implemented prior togo-live

Importance often overlookedLack of archiving leads to performanceissues

RecommendationsDefine archiving strategy and implement WIParchiving prior to go-live to avoid performancedegradation over timeKeep WIP as lean as possible to avoidperformance degradation over timeFor Oracle and SQL server databases, followSAP recommendations for configuration tooptimize performanceRevisit archiving strategy periodically asbusiness changes and usage of SAP MEevolvesLeverage expertise from SAP – SAP Notes andME architecture experts

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RecommendationsBe clear on the purpose and capabilities ofeach tool:– SAP Business Objects– SAP Manufacturing Intelligence and

Integration (MII)– Your company’s standards for reporting

strategy & toolsUnderstand the roadmapLeverage standard reports

Implementation Best PracticesAnalytics and Reporting

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Planning Post-Production Support

SAP ME is typically a 24/7 high availabilitysystem

Production downtimes are costly

RecommendationsStart looking at processes and resources early onAugment existing ERP support process asneededLocate super-users close to the manufacturingfloor

Internal ERP SupportChicago

Sunday 11:00 PM

Plant Floor – Suzhou

Monday 1:00 PM

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Recommendations for ongoing support

RecommendationsImplement solid configurationmanagement across sitesKnow your SAP Account Executiveand Client PartnerStay current on ME versionRe-evaluate sizing andconfiguration when introducingnew products or ramping upproductionMaintain your processes in SolutionManagerMake effective use of downtimePlan for sufficient downtime onupgrades

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© SAP 2007 /

Thank you!

Tim KlimaviczSAP Consulting

SAP America, Inc.1001 Summit BoulevardSuite 2100Atlanta, GA 30319

T +1 [email protected]

mailto:[email protected]

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