X-Change 2007 User Group Conference

Ugan Maistry

Wonderware Shop Floor to SAP Top Floor

using SAP xMII

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Agenda

IntroductionIntroductionIntroductionIntroduction

Real Time Production ExecutionReal Time Production Execution

Real Time FinanceReal Time Finance

SAP xMII – an OE EnablerSAP xMII – an OE Enabler

SummarySummary

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Introducing Operational Excellence

OE is the …Joint/Mutual Achievement of:

Performance ManagementContinuous ImprovementOperational Synchronisation

To optimise production, business processes and product quality enterprise wide

With the aim of …Reducing response times – time to marketAdapting flexibly to market conditionsSuccessfully implementing strategic decisions

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OE Application Examples

Performance ManagementDispatch of GoodsMaintenance Planning

Continuous ImprovementMaterial TrackingInventory Management

Operational SynchronisationProduction Planning

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Traditional Approach to OE

Adding More Silo Applications – Replicating Data, Increasing Complexity and Increasing Costs

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Introducing SAP xMII

The only Composite Application Platform for Mining & Manufacturing Operations

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Composite Application Platform

SA

P x

MII

Adaptive Manufacturing

Manufacturing OperationsSAP Manufacturing (mySAP ERP)

ManufacturingIntelligence

ManufacturingIntegration

Manufacturing Synchronization

“A Single Version of the Truth” across

the Enterprise

Manufacturing Excellence

Reliably produce to target with year-to-year

process and cost improvement

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SAP and Invensys

Invensys achieved SAP certification last yearSAP and Invensys undertaken co-innovation programme

Build on SAP NetWeaver and Invensys ArchestrA as SOA’sDesign and build Packaged Composite Applications (PCA’s)That add real value in attaining Operational Excellence

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Targeted Areas of Co-Innovation

CEO

CFO COO

Business Measurement Business Operation

EnterpriseManagement

ProductionManagement

Plant ResourceManagement

Manufacturing Resource Base

FinancialReporting

Real-Time

Daily

Monthly

Real-Time Finance

Real-TimeAccounting/DPM

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Agenda

Introduction

Real Time Production ExecutionReal Time Production ExecutionReal Time Production ExecutionReal Time Production Execution

Real Time FinanceReal Time Finance

SAP xMII – an OE EnablerSAP xMII – an OE Enabler

SummarySummary

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Real Time Production Execution PCA

Existing Process Control / Machine Control

SA

P N

etW

ea

ve

r ERPPP/PI MM QM PM

SAP EP

BW

My SAP 2005 XI Man Services

RFC/IDOC

xMII

Production Status/ AlertProduction Status/ Alert ManagementManagement

Production Interface Production Interface ““Out of the Box”Out of the Box”

Production Work Production Work Order Handling LogicOrder Handling Logic

SAP Control SAP Control Recipe/Sched Recipe/Sched

Logic Logic

Enterprise

Site

PCA (xApp)Combines SAP xMII + Wonderware’s Production & Performance Management software to deliver sustainable value “Out of the Box”

Prod Work OrderProd Work Order dispatching Servicedispatching Service

Production Production Operation Operation ExecutionExecution

Equipment SetupEquipment SetupManagementManagement

Man OperationsMan OperationsDB/ ServicesDB/ Services

Production WorkOrderProduction WorkOrder TrackingTracking

Data CollectionData Collection

Product DeviationProduct Deviation ManagementManagement

Production Status/ AlertProduction Status/ Alert ServiceService

ProductionProductionPerformancePerformance

Composition•SAP xMII, Wonderware System Platform + Modules•Load PCA to xMII•Load PCA to Wonderware•Configure Equipment

Architecture•Totally Web enabled between Wonderware and xMII•Runs with RFC call for SAP 4.6c / 4.7•Also runs My SAP 2005 Enterprise Services •Two User Interfaces

•Plant Management (UI is xMII)•Plant Floor (UI is InTouch)

Man Services

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Real Time Production Order Creation

From xMII, user opens Prod. Execution Console

Requests a new Control Recipe (Process Order) from SAP PP-PI

PCA logic creates Production Work Order(s)& passes to Wonderware in B2MML format

PCA logic creates Equip. Work Orders for each related equipment for the Production Order

User can view orders and updated status

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Real Time Production Execution

From InTouch on the Plant floor, user can view and execute the orders

User selects equipment to run Work Order on

User selects Prod. Order and activates

User starts Prod. Work Order

System executes and user monitors results

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Production Execution PCA Demo

Live Demo

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Benefits to Customers

Single, composite application to manage production across traditionally separate domains

Alignment of business objective processes and manufacturing operations processes

Increased customer responsiveness & agility from completing the real time demand & supply chain

Optimal customer production scheduling and execution

Improved customer service & satisfaction due to real time order status and production consistency

The bottom-line is continuous bottom-line improvement

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Agenda

Introduction

Real Time FinanceReal Time FinanceReal Time FinanceReal Time Finance

SAP xMII – an OE EnablerSAP xMII – an OE Enabler

SummarySummary

Real Time Production Execution

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Real Time Business Intelligence

Finance EnterpriseManagement

ProductionManagement

Plant ResourceManagement

Manufacturing Resource Base

Real-Time Finance

Real-TimeAccounting/DPM

Measure Context Act

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Real Time Finance

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Real Time Finance

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Real Time Finance

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Real Time Finance

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Real Time Finance

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Real Time Finance

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Benefits to Customer

Financial systems can be used for more than just financial reportingReal Time Accounting/DPM empowers plant floor personnel to behave in a manner that drive business valueReal Time Finance ties the management and executive level into the performance of all manufacturing and industrial assets in real timePlant floor financials are calculated at the speed of the business and more closely represent the truthMeasuring correctly and in real time enables continuous business performance improvement

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Agenda

Introduction

SAP xMII – an OE EnablerSAP xMII – an OE EnablerSAP xMII – an OE EnablerSAP xMII – an OE Enabler

SummarySummary

Real Time Production Execution

Real Time Finance

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SAP xMII – Illustrative ScenarioProduction schedule is sent from SAP ERP to SAP xMII, transmitted to the Manufacturing Operations Management System and displayed on Mfg. Dashboard

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After batch execution, SAP xMII aggregates production performance data and automatically updates SAP ERP inventory

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Based on shop floor automation sensor data and Six Sigma control analysis, SAP xMII detects quality problem, generates alert and quarantines batch in SAP ERP

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Production quality alert appears in Plant Manager’s Dashboard and he drills down into alert to performs a rapid root cause analysis of the problem via SAP xMII

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Plant Manager initiates corrective action to fix the quality problem and resolve exception before it becomes customer issue

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SAP xMII

SAP NETWEAVER

Oth

er S

AP

Bu

s.

So

lu t

ion

s

S

AP

BI

SAP Manufacturing (mySAP ERP)

Manufacturing Intelligence Dashboards

Manufacturing Intelligence

Manufacturing Integration

Alert!

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5. Decide what action: Email report to Product Manager, SMS alert….

2. Find Vehicle(s) created to satisfy Production Order

3. Get Historian and LIMS data for vehicles, run xMII Analytics

4. An SPC Alarm may point to a Vehicle production problem – providing an overview of Customers affected

1. Look up customer PO from SAP & return SAP Production Order

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Example – Customer Response Time

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Example – Metallurgical Accounting

1 2

3

55. Update SAP with

relevant data per process order

2. Retrieve Dry/Wet Masses from Weighbridges, SCADA, DCS etc

3. Calculate Metal Content based on assay analysis and masses

4. Do SPC Analysis to determine variances and improve plant processes

1. Retrieve Assay results from LIMS system

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Visualisation Capabilities

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Visualisation Capabilities

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Agenda

Introduction

SummarySummarySummarySummary

Real Time Production Execution

Real Time Finance

SAP xMII – as OE Enabler

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Summary

SAP and Wonderware utilising SOA for integration

Configurable (not bespoke)Allowing the business the flexibility to change on demandIncrease agility while decreasing maintenance and development costs

PCA’s released are the first of manyBusiness processes and production processes closer aligned with each other

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And most importantly …

If you are an existing Wonderware Manufacturing Operations Management user and an existing SAP ERP user …

You should be using SAP xMII as your Manufacturing Integration and Intelligence Portal of choice!

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THANK YOUFor

Attending

Questions???

X-Change 2007User Group Conference

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Please use these icons in your presentations

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But Gartner Says …

Service Oriented Architecture (SOA)

Enabler for ERP to Real-time systems integrationProviding a realistic chance of attaining Operational Excellence

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Enterprise

SAP NETWEAVER

Oth

er S

AP

Bu

s.

So

lu t

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s

S

AP

BI

SAP Manufacturing (mySAP ERP)

Manufacturing Intelligence Dashboards

SAP xMII

Manufacturing Integration

Manufacturing Intelligence

Manufacturing Integration

• Plan work orders• Check resources • Create mfg plan• Scheduling• Release work order• Close order• Shipping and logistics

Real-time events/alerts Order status Yields Completions and usage Start and stop times Quality and lab data Process history Downtime tracking