end-to-end integrated processes -...

Industry 4.0 – Digitizing the Enterprise Asset ManagementEnd-to-End Integrated Processes

Carlos Portillo

EMEA Center of Excellence - Extended Supply Chain

LoB Connected Manufacturing and Operational Excellence

© 2016 SAP SE or an SAP affiliate company. All rights reserved.

SAP's Vision for Enterprise Asset Management

Provide best-in-class user

experience seamlessly on all

devices.

Help ensure accuracy of

master data and allow for

sharing master data

alongside the value chain

and manage Big Data.

Establish a business network

for OEMs, service providers,

operators, and other

contributors.

Make operational data

available for comprehensive

analytics and insight-to-

action, leveraging the IoT.


Selected End-to-End Processes for Enterprise Asset ManagementExtended Supply Chain Detailed Value Map

Recipe Development

Sourcing

Handover toManufacturing

Design

Orchestration

Authoring ToolIntegration

Product Costing

EngineeringCollaboration

ProductDevelopment

LoB R&D/Eng

Responsive

Manufacturing

ProductionScheduling

Enterprise Performance Management

Lean Manufacturing

ProductionWarehouse

Discrete Manufacturing Orchestration and Execution

Quality Management and Compliance

Production Planning

LoB Mfg

Project and

Portfolio

Management

PortfolioManagement

Project Connectivity

ProjectManagement

Resource Management

Idea Management

LoB R&D/Eng

Asset

Network

Asset Operations

and Maintenance

Environment,

Health,

and Safety

Asset Planning and Scheduling

Maintenance Execution

Mobile AssetManagement

Asset Strategy and Performance

Health and Safety Management

Maintenance Safety and Permit to Work

EnvironmentManagement

Managementof Change

Incident Management

Asset Information Governance

Predictive Maintenanceand Service

Asset InformationCollaboration

LoB Asset Management

Product Safety

and Stewardship

Corporate

Sustainability

Product and Chemical Comp-liance for Process Industries

Global Label Management

Safety Data Sheet Management

Dangerous Goods Management

Product Compliance for Discrete Industries

Sustainability Reporting andPerformance Management

Product and SupplierSustainabilityAssessment

Ridesharing

Energy Transparencyand Performance Management

LoB Sustainability

LoB R&D/Eng

Real Estate

Management

Portfolio and Lease Management

Energyand Safety

Space Management

Maintenance and Repair

Investment andConstruction

LoB Finance


Increase

effectiveness

Increase

efficiency

Time, effort or cost

is well used for the intended

task or purpose

Effectiveness is the capability

of producing

a desired result

Bring Business Context to Your Operational Data

Condition MonitoringRemote Service

Fault Pattern

Recognition

Machine Health

Prediction

Create Maintenance

or Service OrderSchedule Order

Execute Order

on mobile deviceVisual Support

IT / OT

Convergence


Assets in the Field (External Scenarios) Assets in Shop Floor / Operations (Industrial Scenarios)

PCo

MII3D VE

PdMS3D VE

ERP

LAM

EHS

WCM

MRS / Click

Work Manager3D VE

IoT Client • Machine / Asset Integration• Device / Asset Integration

• Real time Asset Performance KPIs

• Condition-Based Maintenance

• Automatic Actions upon events

• Virtualization

• Measuring Point linked from PM

• Energy Monitoring

• Preventive Planning

• Maintenance Notification

• Maintenance Order Creation

• Measuring Point linked with MII

• Predictive Maintenance

• Asset Health Monitoring

• Machine Learning

• Vibration Analysis

• Virtualization

• Relevant Risks

• Safety Measures

• Work Clearance

• Control Inspections

• Management of Change

• Incidents Management

• Resource Allocation / Scheduling

• WO Scheduling

• Maintenance Order Execution

• Visual work instructions

• Augmented Reality

AINAsset

Manufacturer

Service

Provider

• Central hub for linking equipment in a

collaboration ecosystem

Assets

Maintained in PM

3D VE

End-to-End SAP EAM Architecture Overview

MoC


SAP 3D Visual EnterpriseVirtualization and 3D Guided Work Instructions

R & DVisualization

ManufacturingInstructions

Sales & MarketingCatalogs

ServiceMaintenance

FacilitiesMgmt.

• Improved internal &

supplier collaboration

• Fewer ECNs due to

concurrent processes

24% Faster supplier

response

• Faster training

• Reduced rework

• Faster cycle time

• Flexible workforce

• Reduced warranty cost

45% Reduced rework

• Improved

customer satisfaction

• Higher after market

sales

• Reduced part returns

• Improved plant uptime

• Predictive analytics

• Faster response time

• Fewer accidents

79% Lower accident

frequency

• Improved repair

time

• Lower training

costs

• Consistent global

service standards

70% Fewer part returns

55% Improved asset

utilization

25% Reduced call center

demand

10% Faster time to market

50% Faster training

75% Faster work instruction

creation & maintenance

10% Fewer engineering

changes


SAP 3D Visual EnterpriseVisual Maintenance Procedures

Using visualization:

• Provides visual maintenance review capabilities

• Improves maintenance efficiency, reduces line and equipment downtime

• Reduces risk of non-compliance and injury due to human error

• Speeds new hire training


SAP 3D Visual EnterpriseVisual Maintenance Procedures

The plant as the interface:

• Increase operator efficiency to find equipment records, create work orders, etc

• Reduce operator error, contain risk and improve compliance


SAP offerings for SAP Predictive Maintenance and Service

HANA Cloud Platform HANA On-Premise

SAP Predictive Maintenance and Service,

Cloud Edition


Technical Foundation (RCS)

SAP Custom DevelopmentExtensions *

Cloud Edition On-Premise Edition

HANA On-premise


On-premise Edition

Extensions *

- On-premise edition was released as a

standard solution, March 15, 2016.

- Market Launch at Hanover Fair

* Extensions from SAP CD,

Partners and Customers


Solution Capabilities Remote device and message management

Condition monitoring and analysis of sensor data

Visualization of machine KPIs and drill-downs

Geo map visualization of warnings and alerts

Integration with Machine learning tools

Vibration Analysis for rotating equipments

Integration with business systems (e.g. ticketing)

Scalable SaaS offering

Hana Cloud Platform for extensions (e.g. customerportals)

PdMS cloud editionRemote Condition Monitoring


Geo-

Spatial

Insight

Provider

Asset

Explorer

Insight

Provider

Key

Figure

Insight

Provider

3D

Visualizat

ion

Insight

Provider

Predictive Maintenance and Service

Data Management Data Processing

Work

Activities

Insight

Provider

Derived

Signal

Insight

Provider

SAP HANA SAP IQ SAP Data Services* SAP ESP*

*Optional components

Asset Health Control Center (AHCC)

Extendable

by additional

Custom

Insight

Provider &

Custom Data

Services

Predictive Maintenance and Service On-Premise Edition

Connected

Assets

Devices,

machines,

sensors

Integration

possible with

Telit

DeviceWise,

SAP PCo

Process

Automation

Closed-loop

business

process

integration

into PM and

MRS

IT

Integration

Remaining

Useful Life

Prediction

Distance-

Based

Failure

Analysis

Anomaly Detection with Principal Component Analysis

Data Science ServicesInsight Provider

OT (Device)

Integration

IoT

Ap

pli

cati

on

s

Op

era

tio

nali

zed

An

aly

tics a

nd

Data

Scie

nce

Serv

ices

IoT

Base

Serv

ices

Big

Data

Pla

tfo

rm

Asset Health Fact Sheet (AHFS)

Components

Insight

Provider

PdMS on-premise editionDriving Scale - Business Applications Built on Modular Analytics

Data Fusion

Storage Data ingestion


PdMS on-premise editionOut-of-the-box Data Science Defined – Applicable Use Cases

Anomaly Detection

• Apply Principal Component Analysis to

sensor data to identify the ‘outliers’,

those items or events which do not

conform to the expected pattern

• Automatic detection of multivariate

anomalies, which could lead to failures

in components

Distance-Based

Failure Analysis

• Store ideal state “snapshot” of

component, compare against regular

capture of current state snapshot

• Comparison analysis can result in early

malfunctions in order to reduce

downtime

Remaining Useful

Life Prediction

• Conduct Weibull Life Time Analysis

on captured repair data to estimate

component lifetime

• Calculate remaining useful life and

probability of failure for each

machine/component and store

scores in time series storage

P Q

PCA


SAP Work ManagerExecution of Maintenance Orders in any Mobile Device

© 2016 SAP SE or an SAP affiliate company. All rights reserved. 15Internal

Applications

Pump OEM

Valve OEM

Service

Provider

Chemicals

Mill

Consumer

ProductsContent Integration Network

OEMs & Service Providers Operators

Shared Model Database

Global Equipment Registry

Business PartnerNetwork Services

An Asset Network to bring together Business Partners


Shared Model Database

Global Equipment Registry

An Asset Network to change Business Processes

Business PartnerNetwork Services

Service Bulletins, Recalls & WarrantyManage

Equipment as a Service

Usage based Design Enhancements

Quality, Inspection & Calibration

Results Sharing

MRO VisualSpare Parts content

Global Job Catalogue, Visual Work Instructions

& Task Lists

Visual audit and name plate recognition

Analyse Equipment performance

Business Context for Predictive Maintenance

Collaborative work execution & results sharing

© 2015 SAP SE or an SAP affiliate company. All rights reserved. 17Customer

Asset Intelligence Network high-level architecture

Manufacturer apps Asset lifecycleTicketing/

notifications

Joint work

schedulingBenchmarking Parts verification Knowledge base

Predictive remote

maintenance

Man

ufa

ctu

rer

sid

e

Nameplate info

Service bulletins & revs

Maint./inspection strategy

Structure/parts

Recalls

Op & maint. instructions

Failure modes

Safety controls

Process controls

Designs & drawings

Measuring point

Product training

Licensing

Design improvements

Installation parameters

de

fin

eco

ntr

ol

op

era

teim

pro

ve

CollaborationNetwork learning on assets

SecureAnonymized information for

industry-wide comparisons

ContentConsume any information from any

party using a standardized taxonomy

OpenAny manufacturers and customers

1

2

3

4

Publish Subscribe

Measurement/telemetry

Usage information

Installation information

Failure/incident data

Service bulletin processing

Risks and controls

Design recommendations

Recall processing

M2M / IOT initiative

Maintenance history

de

fine

co

ntro

lo

pe

rate

imp

rove

Reviews

Op

era

tor s

ide


SAP Multiresource SchedulingArchitecture Overview – Integration makes a Difference

HR Resources

Business Partner

Availability, Qualifications

Demand

Supply Assignments

SAP ERP

PM/CS

Work/Service Order,

Notification

SAP ERP PS

Project System

SAP PPM

cProjects

SAP Applications

SA

P M

RS

GIS Geographical

Information system

Equipment

Tools

Spare Parts

Optimizer

SAP VSR Vehicle

Scheduling & Routing

SAP CRM

Service Order

SAP HCM, MM

Qualifications

DE

MA

ND

SU

PP

LY

SAP Mobile Platform

SAP Work Manager and

Service Manager by Syclo

SAP BW, SAP

BusinessObjects, SAP

Predictive Analysis

ANALYTICS

MOBILITY

Work Centers

Groups

Crews


Augmented Reality with SAP AR Service Technician

Companion Application to SAP Work Manager

Link to the SAP Work Manager mobile app through a simple

QR-code scan

Visual Enterprise 3D model visualization and animation

SAP 3D Visual Enterprise steps browsing

Equipment notes

Remote expert calling

Hands-free application

All the application steps can be completed without gestures

or touch events

Required inputs are managed through voice recognition


Questions??


Thank you

Contact information:

Carlos PortilloEMEA Center of ExcellenceLoB Manufacturing & Operational [email protected]+31 615 3489 07

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