Ralf Lehmann | EMEA Center of Excellence Manufacturing, SAP Deutschland AG & Co KG
April 2013
SAP Manufacturing Innovations in the Shop Floor
© 2013 SAP AG. All rights reserved. 3
Manufacturing Video Opener 2013
© 2013 SAP AG. All rights reserved. 4
Legal Disclaimer
The information in this presentation is confidential and proprietary to SAP and may not be disclosed without the permission of SAP. This
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The information on this document is not a commitment, promise or legal obligation to deliver any material, code or functionality. This
document is provided without a warranty of any kind, either express or implied, including but not limited to, the implied warranties of
merchantability, fitness for a particular purpose, or non-infringement. This document is for informational purposes and may not be
incorporated into a contract. SAP assumes no responsibility for errors or omissions in this document, except if such damages were
caused by SAP intentionally or grossly negligent.
All forward-looking statements are subject to various risks and uncertainties that could cause actual results to differ materially from
expectations. Readers are cautioned not to place undue reliance on these forward-looking statements, which speak only as of their
dates, and they should not be relied upon in making purchasing decisions.
© 2013 SAP AG. All rights reserved. 5
The Perfect Plant: Challenges today
VP Manufacturing VP BU
CIO
VP Operations VP Sales
Disconnects
Ensure compliance with internal
and external regulations and
corporate initiatives
Align strategy and execution
through Manufacturing analytics
Maximum process agility with
reduced cost and improved quality
Effectiveness & Efficiency Responsiveness Compliance
© 2013 SAP AG. All rights reserved. 6
SAP Manufacturing Strategy and Vision From perfect orders to perfect plants
Our intention is to minimize disruption caused by any kind of disconnects …
… to increase productivity and efficiency by
- Higher transparency
- Faster Reaction to Changes
- Adequate inventory levels
- Reduced Production Cost
Global Orchestration
From Business Strategy to Production
Visual Manufacturing Engineering
Production Planning and Scheduling
Manufacturing Network Collaboration
After Market Sales & Service
Local Execution
State of the art Plant Execution
Fully integrated Make & Move
Visual Manufacturing with Right
Hemisphere
Real World Integration and Mobility
Man
ufa
ctu
rin
g P
erf
orm
an
ce
Man
ag
em
en
t R
ea
l-tim
e a
nd
pre
dic
tive
in
telli
ge
nce u
sin
g H
AN
A
… across the value chains ...
© 2013 SAP AG. All rights reserved. 7
There are multiple options for SAP in the Shop Floor
SAP MII
SAP ERP
SAP PCo
SAP ME
Machine Entry ME POD
SAP MES SAP MII with or without Worker UI*
SAP ERP
SAP MII
Worker UI* Machine Entry
SAP PCo
* Planned shipment in Q2 / 2013
Shop Floor
Enterprise
Range of use
» Manufacturing Execution
System
Target Industries
» Discrete Industries
Highlights
» Tracking & Tracing
on SFC / Serial Number
» Non Conformance Handling
» Interlocking
» Production Data Acq.
» KPIs, Reporting & SPC
» Highly Extensible
Range of use
» Integration & Intelligence
» Reporting & Analytics
» Individual Scenarios and Use
Cases
» Worker UI*
Predefined MII Content for Data
Collection for less complex
scenarios
Target Industries
» All Manufacturing Industries
Highlights
» Highly Extensible
© 2013 SAP AG. All rights reserved. 8
SAP Integrated Manufacturing Solution
Production Planning and Scheduling
Manufacturing Execution
Quality Planning and Control
Performance Visibility and Monitoring
ERP PP
APO PP/DS Shop Floor Dispatching and
Monitoring Tool
MII
ME
ERP QM
ME
QIM
ERP
MII
ME
Dashboards
BOBJ
© 2013 SAP AG. All rights reserved. 9
Manufacturing Solution Portfolio Seamless Integrated Solutions
» Product and process visualization » Product structure synchronization » Process planning
Manufacturing engineering
» EH&S » Energy management
Sustainability and safety
» Asset operations » Asset maintenance
Asset management
» Work order collaboration » Critical data exchange
Outsourced manufacturing
Outsourced
manufacturing
Manufacturing
Integration and
Intelligence
Manufacturing
Execution
Production
Planning Quality
Management
Asset
Management
Sustainability
and Safety
Manufacturing
Engineering
» Marketing and lead management » Dealer business management » Vehicle sales management » Aftersales support and service
Manufacturing Integration
and Intelligence (SAP MII)
» MES for discrete industries » Production control for process industries
Manufacturing execution
» Production planning » Lean manufacturing » Production order management » Detailed scheduling
Production planning
» Quality engineering & planning » Quality inspection » Quality notifications » Quality improvement » Audit management
Quality management
SAP MII SAP Manufacturing Integration and Intelligence
© 2013 SAP AG. All rights reserved.
Trends
» EMI (Enterprise Manufacturing Intelligence)
» Process and system harmonization
» Traceability, process enforcement
» GREEN, Energy Management
Customer Challenges
» Transparency and Interoperability
» Semantic Business Layer
» Sustainable Manufacturing
Energy, Visibility
Corp
ora
te
Pla
nt (d
ece
ntr
al)
SF
AC
PLC DCS PLC PLC DCS …
SAP Manufacturing
Ralf Lehmann | EMEA CoE SAP Manufacturing
SAP Manufacturing Whiteboard
Business
Suite BW
Composites Analytics
SCADA DB MES Historian SFD Maint-
enance
© 2013 SAP AG. All rights reserved.
Trends
» EMI (Enterprise Manufacturing Intelligence)
» Process and system harmonization
» Traceability, process enforcement
» GREEN, Energy Management
Customer Challenges
» Transparency and Interoperability
» Semantic Business Layer
» Sustainable Manufacturing
Energy, Visibility
Corp
ora
te
Pla
nt (d
ece
ntr
al)
SF
AC
PLC DCS PLC PLC DCS …
Benefits
» Integrated MFG Solution
» Out of the box integration
» Transparency
» Composites
» Operator dashboards
» RDS available
Ralf Lehmann | EMEA CoE SAP Manufacturing
SAP Manufacturing Whiteboard
Business
Suite BW
SCADA DB Historian Maint-
enance
HANA
Customer Success
» Valero, 220 M$ / year
» Caterpillar, ABB
» Coca Cola
» Pepsi Corporation
» Sika: RDS BM
» Phillips, 50% Quality improvement
SAP Manufacturing
Mobile
Intelligence Integration Innovation
SAP ME SFD
SAP MII PCo
© 2013 SAP AG. All rights reserved.
SAP MII Product Roadmap 2011-2014 Planned Product Release Timeline
SAP MII 14.0
SAP MII 12.0
SAP MII Planned
Q3 Q1 Q2 Q3 Q4 Q1 Q2 Q4 Q1 Q2 Q3 Q4
2012 2013 2011
Q1 Q2 Q3 Q4
2014
GA RTC
RTC GA
GA RTC
» Self service End User Composition Environment
» MII Facelift with CVOM and UI 5 (new UI5 snippets instead of applets)
» Integration of Plant Information Catalogue with ERP PP, PM
SAP MII (Planned*)
USER EXPER, MULTI-INDUSTRY, SAP TECH, PLATFORM
* Projected release dates and scope are not yet in planning stage therefore is subject to change.
© 2013 SAP AG. All rights reserved.
Outlook: SAP MII Self Service Composition Environment For real-time and flexible business intelligence
» Browser Based Design Time for the End User to easily create Dashboards
/ Reports for analysis of various kinds of Manufacturing Data via Drag &
Drop:
» “Real-time”-Information from the shop floor like Pressure, Temperature,
etc. – Using the Plant Information Catalogue
» Data out of other systems like ERP / SCADA / Data Historians etc.
» Flexible Reporting / Dash boarding provides high transparency
» Adapt reporting / dash boards always to the latest needs / bottlenecks
without the need of IT personnel
Planned innovations
Solution Enhancements Key benefits
© 2013 SAP AG. All rights reserved.
Outlook: SAP MII on HANA
» High performing In-Memory Analytics for large amount of Data (“Big Data”)
» HANA provides the ability to store a significant and broader selection of
manufacturing data for more thorough analysis and more complex
comparison of data.
» HANA provides various statistical algorithms for deep analysis, clustering
and prediction
» The ability to manage large volumes and multiple types of data provides
ability to develop, train and utilize predictive techniques (e.g., regression
and heuristic) for forward looking analysis.
» New insights into the shop floor based on trends / prediction with HANA
capabilities
» Enables near real time analysis of shop floor data to identify preventive
actions
Planned innovations
Solution Enhancements Key benefits
© 2013 SAP AG. All rights reserved. 16
Real-time Shop Floor Status
© 2011 SAP AG. All rights reserved. 17
Automated production from finished product to ERP – PP at Femsa Coca-Cola
© 2011 SAP AG. All rights reserved. 18
Automated label print with barcode at Femsa Coca-Cola
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Real time tracking of production plan at Femsa Coca-Cola
SAP ME SAP Manufacturing Execution
© 2012 SAP AG. All rights reserved. 21
Ma
nu
factu
rin
g F
un
cti
on
ali
ties
SAP Manufacturing Execution Solution Suite Overview
SAP Manufacturing Execution
» Manages and controls manufacturing and shop floor operations
» Integrates business systems to the shop floor
» Complete component and process traceability across global
operations
© 2012 SAP AG. All rights reserved. 22
Integrated User Interface high volume/low mix, make-to-stock, repetitive manufacturing
■ Modular plug-in and layout configuration
■ Highly configurable to meet the disparate
needs of the shop floor w/out custom coding
■ Transact at both the production unit and
operation levels
■ Filter work by production unit,
operation/resource, or work center/end item
number
■ Updated design to reflect modern “look and
feel”
■ Modular configuration supports customer
process/workflow requirements
■ Support for multi-mode manufacturing in
both high volume and complex assembly
environments
■ Ease of setup and configuration allow a
build
Key Features and Benefits
© 2012 SAP AG. All rights reserved. 23
SAP ME Routing Enforcement and Process Assurance
■ Ability to create, edit and modify a
manufacturing route
■ Ability to support alternative and sequential
operations, add conditions and logic,
automate actions and nest multiple routes
into a single operation
■ Ability to display route in a graphical or
tabular format
■ Execute build plan and enforce route
enabling process control
■ Graphically model build plan to optimize user
experience
■ Automate actions for shop floor operators
and conditions based on manufacturing
events
■ Reduce errors and improve quality
Key Features and Benefits
Alternate Operations
Conditional Routing
Automatic Actions
Routing Logic
Sequential Operations
Nested Routings
© 2012 SAP AG. All rights reserved. 24
Device History Report — Unit-Specific, As-Built Data
■ Complete “as built” record in a single report
■ Electronic Device History Report
■ Tree structure for drill down capabilities
■ Ability to retrieve and display data as
needed
■ Direct link to As Built Summary Report
■ Enhanced support to view archived product
genealogy
■ Complete process and component level
traceability
■ Complete genealogy in a single view
■ Maintain customer and regulatory
compliance
■ Rick mitigation for recall exposure
■ Strengthens support for industries mandated
by heavy regulatory compliance
Key Features and Benefits
SAP Confidential
© 2012 SAP AG. All rights reserved. 25
Your Choice: Paper vs. E-DHR
E-DHR: Electronic Device History Report
© 2012 SAP AG. All rights reserved. 26
SAP ME Unit Level Traceability
Operators via User Interfaces Machines via Web Services Auto-assembled Components
Whatever way you choose, the component information
is logged and is available at any time via...
SAP ME supports various ways to collect component data
© 2012 SAP AG. All rights reserved. 27
SAP ME Backward Traceability
Tough it may happen that a component is defective. This means that units that contain this component may potentially be defective. All you need
it to quickly find all units that use the component with particular assembly data.
Just select what data
you are looking for
and task the system
to find it for you...
SAP ME Component Usage Report gives you full components to material level visibility
© 2013 SAP AG. All rights reserved.
SAP ME Touch Screen POD
» Support for various touch devices including monitors and tablets
» Minimum supported resolution is 1024x768
» Simplified, touch-friendly screen navigation
» Graphical status indicators
» Better readability
» Sound alert upon error display
» Button change when process is complete
» Icon and text on the button
» Ergonomically sized touch buttons and fields
» Slide menus and pagers
» New table layout
» Visibility where the product is in the process
© 2013 SAP AG. All rights reserved.
SAP ME Touch Screen POD
3D Models
» Visual Enterprise Viewer (the former Right Hemisphere technology) is now
embedded into the POD as a Work Instruction plug-in
» View 2D/3D models that can be created in the Visual Enterprise suite as a
.RH file format
» Scenarios:
» Assembly
» Visual Test and Repair
HTML Pages
» Viewing of an image or HTML page
in a POD plug-in
» Can be used e.g. to view MII reports
and dashboards within the
context of the ME POD
Planned innovations
Solution Enhancements Key benefits
» Allows the shop floor operator to have an interactive experience with
2D/3D models w/out having to leave the POD
» Flexibility to provide various kind of content to the operator
© 2013 SAP AG. All rights reserved.
SAP Manufacturing Execution „Out-of-the box“ Integration with SAP ERP
» Communication based on Web Services,
BAPI, RFC
» MII for Integration, Extensions and Customizations
» End-to-end Process Integration between SAP ME
and ERP
» Extend-able and customizable scenarios support
Master/Transactional Data Transfer End-to-End Process Integration
SAP OEE SAP Overall Equipment Effectiveness (OEE)
© 2013 SAP AG. All rights reserved. 34
Overall Equipment Efficiency on HANA Architecture Overview
Central repository enables global
visibility with full drill-down
Use of raw data instead of complex
aggregation and synch mechanisms
Real-time execution of complex KPI
calculation algorithms
Direct machine connectivity to collect status
information etc
Data buffering at plant level through
MII/PCo
© 2013 SAP AG. All rights reserved. 35
SAP Overall Equipment Effectiveness (OEE) Real-Time Visibility to Production Performance
» Real-time visibility and monitoring of performance metrics
» Production data combined with business data
» Real-time calculation and presentation of OEE metrics
» Real-time alerts and notification of production issues
» Simple, touch screen user interface
» Add qualitative comments and context
» Connectivity to disparate plant systems and data sources
» Automated, real-time data collection
© 2013 SAP AG. All rights reserved. 37
SAP Overall Equipment Effectiveness (OEE) Enterprise OEE for Broader Supply Chain Improvement
Plant - 2
ECC
Plant - N Plant - 1 Plant - 3
HANA
» Single, common framework for all plants
» Enterprise wide repository of data
» Cross plant performance comparison
» Combined with business context
» Broader business implications of performance loss
» Framework for broader set of performance capability
and improvement
© 2013 SAP AG. All rights reserved. 38
SAP Overall Equipment Effectiveness (OEE) Comprehensive Solution Approach
Configurable
Operator
Dashboard
Centralized
OEE
Configuration
Cross Plant,
Business
Context-
Related
Analytics
Simple Operator UI and Data Entry
© 2013 SAP AG. All rights reserved. 39
© 2013 SAP AG. All rights reserved. 40
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OEE Plant UI Record Scheduled Downtime
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OEE Plant UI Order Dispatch
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OEE Plant UI Real-Time Dashboard – Order Selection
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OEE Plant UI Real-Time Dashboard – Monitor Production
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OEE Plant UI Real-Time Dashboard – Multiple Orders
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OEE Plant UI Real-Time Dashboard – Data Collection
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OEE Plant UI Real-Time Dashboard – Review and Confirm Order
SAP SFD&M SAP Shop Floor Dispatcher and Monitoring
© 2013 SAP AG. All rights reserved.
New Features in SAP MII 14.0 Performance Management Enhancements
» Overview of planned manufacturing tasks per work center
» Easy and intuitive assignment of manufacturing tasks to machines via
visualization of alternative machines, order and operation dates
» Visualization of production program for individual / all machines
» Monitoring functions such as confirmation progress, status of predecessor
tasks, display of important due dates/times, machine breakdowns,
overload situations, visualization of high-priority orders, alert monitor
» Set of open interfaces/BAdIs
» New, highly interactive UI for production supervisors or supervisors
supporting state-of-the-art UI techniques
» Decision support for order assignment to individual resources
» Quick reaction to unforeseen events
» Standard integration: no need to integrate third-party tools
» Based on available data structures in SAP ERP
Solution Enhancements Key benefits
New innovations
© 2013 SAP AG. All rights reserved. 54
Dispatching – Overview
Customizable visualization of
order & operation dates
Alert Indicator
Visualization of alternative
machines
Overlapping Production Tasks Wait Time
Detailed
Information
© 2013 SAP AG. All rights reserved. 55
Monitoring – Overview
Visualization of
wait time Refresh Manipulation
of colors
Visualization of
machine events
Confirmation
status Visualization of
non-working time
© 2013 SAP AG. All rights reserved.
SAP Shop Floor Dispatching and Monitoring Tool Planned Innovations
» Integration to SAP ME
» Integration to Worker UI
» Inclusion of maintenance orders
In the future support of
» Repetitive Manufacturing
» Process Manufacturing
Faster decision support for users and higher performance
Solution Enhancements Key benefits
Planned innovations
SAP Mobility
© 2013 SAP AG. All rights reserved. 64
Mobile Demo Screen
MOBILE DEMO
VISIT THE SAP CHANNEL AT : http://www.youtube.com/SAPVideoMOM
© 2013 SAP AG. All rights reserved. 66
SAP Manufacturing in Social Media Follow us and stay tuned
YouTube Channel for Manufacturing
Watch manufacturing customer success references, leanr about intereting topics
and news with the videos shared on the oficial channel from SAP Manufacturing.
Link: http://www.YouTube.com/SAPVideoMOM
Enterprise Manufacuring Operations on Facebook
Wanted to be informed whenever important topics related to manufacturing come
out? Wanted to get latest news in your facebook account? Please join the facebook
page for SAP Manufacturing. Link: http://www.facebook.com/SAPMFG
SAP Manufacturing on Twitter
Interest in receiving manufacturing tweets from SAP? Please join the twitter channel
for SAP Manufacturing and stay tuned. Link: http://www.twitter.com/SAPMFG
Enterprise Management Operations
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Questions to the community of just interested in ongoing discussions? Join us.
Thank You!
Contact information:
Ralf Lehmann
Center of Excellence EMEA
Line of Business SAP Manufacturing
SAP Deutschland AG & Co. KG
© 2013 SAP AG. All rights reserved. 68
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