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SAP Manufacturing ExecutionEnabling Technologies for Performance, Integration, and Flexibility
October 2011
Overview
Performance/Scalability
Extensibility
Agenda
© 2011 SAP AG. All rights reserved. 2Confidential
Extensibility
Integration
Q&A
Aerospace & Defense
High Tech Automotive& Auto
Medical DeviceIndustrial Machinery &
Serving Discrete Industries with a Single MES Platform
© 2011 SAP AG. All rights reserved. 3Confidential
Defense & Auto Electronics
Machinery & Components
low volume/high mix
build-to-order assembly
high volume/low mix
repetitive manufacturing
Why Is Technology Important For MES?
MES System Reliability
Increasing Product Complexity
Extended & Distributed Supply Chains
© 2011 SAP AG. All rights reserved. 4Confidential
Accelerated Use of Devices and Sensors
Increasing Amounts of Data Being Collected
Lowering of IT Infrastructure Costs
Key Technologies
Virtualization and Cloud Computing
Data Storage & Movement
Product Platform Architecture
� Support Any Device or Manufacturing Equipment
© 2011 SAP AG. All rights reserved. 5Confidential
� Support Any Device or Manufacturing Equipment
Standards Based Integration Services
ME Software Development Kit
Overview
Performance/Scalability
Extensibility
Agenda
© 2011 SAP AG. All rights reserved. 6Confidential
Extensibility
Integration
Q&A
Plant Locations ERP Data CenterRegional Data Center
ME, MII System Landscape Models
MIIME
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ERP
MIIME
MIIME
Consideration Central Local Comments
Initial investment Duplicating high availability is costly
Operational cost Maximize utilization / cost absorption
Change managementConsistent IT policies easier to implement
Centralized data repository Cross site reporting / moving data
Multi-Site Landscape Consideration
© 2011 SAP AG. All rights reserved. 8Confidential
Centralized data repository Cross site reporting / moving data
Integration to ERP / other apps Less costly and centrally managed
Optimal performance WAN performance & reliability
Downtime riskStandalone operation / local response from IT support
Highly automated manufacturing Response time is critical
Remote plants WAN performance & reliability
Local controlRecommend enforce consistent configuration and change control
ME System Landscape
© 2011 SAP AG. All rights reserved. 9Confidential
High Volume, Enterprise Deployment
NetWeaverInstance
SAP ME
APPLICATION SERVER
NetWeaverInstance
SAP MIISAPMEINT
APPLICATION SERVER
SAP MEWIP Schema
DATABASE SERVER
DatabaseInstance
SAP MEODS Schema
DATABASE SERVER
DatabaseInstance
© 2011 SAP AG. All rights reserved. 10Confidential
Scalability high transaction volume by addition of application servers
Servers can be virtualized
Redundancy for high availability
Multiple physical servers and application servers
24x7 operations with failover requirements
SAP MESAPMEINT
ODS Schema
SAPMEINTSchema
Alternate Landscape – Low Volume Deployment
Low Volume
� Single manufacturing site
� Low volume manufacturing
– Complex Assembly
DATABASE
SERVER
SAP ME
WIP Schema
Database
Instance
SAP ME
APPLICATION
SERVER
© 2011 SAP AG. All rights reserved. 11Confidential
Less Physical Servers
� Servers with multiple processors
� Redundancy at hardware level through
vendor strategies (e.g. HP Service Guard)
SAP ME
ODS Schema
Database
Instance
SAPMEINT
SchemaSAP MII
SAPMEINT
ME System Landscape Sizing
Key information inputs are
� Manufacturing routing steps requiring ME tracking
– Number of data collections per step
� Key master data size – BOM, Shop Orders
� Daily product volume
� Daily production shift schedule
© 2011 SAP AG. All rights reserved. 12Confidential
System Sizing Tool exists to forecast system load and database size
� Calculates Transactions Per Minute (TPM)
� Calculates database size for WIP database based on retention period
Server sizing is based on forecasted TPM
� Internal benchmarking of TPM on various server landscapes
– Single vs. multiple App servers, single vs. multiple CPUs, different Operation systems
� Data used to decide “T-shirt” sizing of servers (small, medium, large)
Data Center
WAN System Landscape and Components
NA Site
Landscape
NA Site
Landscape
Dev/Test ECC
Dev/Test Change Mgmt
S/W Migration
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Prod ECCEurope Site
Landscape
Asia Site
Landscape
Asia Site
Landscape
App Server
Oracle DB Server
App Server
Solution Manager
Global ODS
Business Objects
Global ODS extracts from sites
WAN
ODS Database
Operation Data Store (ODS) Schema
Audit Log Schema
WIP Database Global ODS Database
SAP ME Data Flow and Reporting
Master
DataAudit Log
Configuration
Changes
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Archive Schema
MII DashboardsWeb Based Reports
MII Dashboards
BOBJ
14 Universes
25 Reports
BOBJ
14 Universes
25 Reports
Production
Data
Product
Data
ODS Extracts
Archive
UnArchive
Detail Data ETLSummarized
Metrics
Archived
Product Data
CopySummarized
Metrics
ME ODS Data Rollup
Production metrics summarization for ODS
� Data extracts for specific types of manufacturing data
� Option to keep detailed records or delete after summarization
� Summarization configurable based on specific data elements
– Time granularity is a key summary key
� Business Objects Universes can be shared for modeling in other BI tools
Global ODS aggregates data from site level ODS
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Global ODS aggregates data from site level ODS
Data Extract Material Operation Resource Router SFC Shop Order Time
DPMO X X X X X X X
Nonconformance X X X X X X X
Labor X X X X X X X
Production Quantities X X X X X X
Yield X X X X X X
Order Cycle Time X X X X X X
Resource Utilization X X X X X X X
Sample Summary Options
Application Server Load Balancing and Failover
APPLICATION SERVER
APPLICATION SERVERNW Web Dispatcher or
Hardware Load Balancer
Clients
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SAP MENetWeaver Instance
SAP ME
ME High Availability
Application Server
� Multiple physical servers combined with load balancer provides failover in case of hardware
or software failures
� Load balancer contains heartbeat monitoring
– Detection of hardware failure
– Detection of NetWeaver AS Java server failure
� Load balancers typically are paired to protect against load balancer failure
© 2011 SAP AG. All rights reserved. 17Confidential
Database Server
� DB Vendor specific strategies
– Protection against physical server failure
– Protection against data corruption (disk, I/O, etc.)
� Allows failover to standby database server in the event primary database fails
� Recommend addressing physical server failover with hardware vendor because of the many
options
Performance Benchmarking
ME Performance Requirements
� Sub-second response time requirements for key production transactions
� Mixed manufacturing configurations of ME product
� Record response time as well as overall system throughput
� Track min, max, std dev, and average values
ERP Integration Performance Testing
© 2011 SAP AG. All rights reserved. 18Confidential
� Inbound messages for master data download
– Material, BOM, Router, Production Order
� Outbound messages
– Confirmations, Backflush, Equipment Status, Inventory
Testing Landscape
� Different database vendors
� Different application server versions
� Different product servers
Performance Testing – CPU Load
© 2011 SAP AG. All rights reserved. 19Confidential
Overview
Performance/Scalability
Extensibility
Agenda
© 2011 SAP AG. All rights reserved. 20Confidential
Extensibility
Integration
Q&A
Why are application platforms important?
Application By The Numbers…
� 248,000 Apple App Store
� 550,000 Facebook
� 250,000 Twitter
� 210,000 Salesforce.com
New platforms are dramatically more efficient for creating applications
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� Utilize standard technology
� Robust application APIs available through Web Services
� Web Services provide access through any technology (.Net, Adobe Flex, etc.)
� Enabled by cloud infrastructures
Enables value added functionality to be developed outside of SAP
� SAP customers
� SAP partners
ME Platform Objectives
Provide common enterprise solution
Meet local requirements
Minimize cost of ownership
Configuration
Extensions
© 2011 SAP AG. All rights reserved. 22Confidential
Minimize cost of ownership
Enable market specific solutions
Support complex integration scenarios
Core Product
ME Extensions Mechanisms
User Interface• UI Configurability
• Operator Workflow
• Plugin Configuration
• Activity Definitions
• POD Plugins
• Business Object Configuration
Configuration Extensions
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Business
• Business Object Configuration
• System Rules
• Activity Options
• Hook Points
• Exist Points
• Application Business API
Data
• Initial Data Load Templates
• Custom Field Definitions
• Data Type Definitions
• New Business Objects
• Custom Database Tables
NetWeaver Application Server (NWAS)
SAP ME Enterprise Application (SCA)SAP ME Enterprise Application (SCA)
Service LayerService Layer
Presentation Layer Web Services LayerWeb Services Layer
Configuration Configuration Maintenance Maintenance ProductionProduction
Master DataUIs
Master DataUIs
ProductionUIs
ProductionUIs
Maintenance Web ServicesMaintenance Web Services
ProductionWeb Services
ProductionWeb Services
Service Locator Service Locator Collaboration FrameworkCollaboration Framework
PluginsPlugins
Internals of ME Layered Architecture
© 2011 SAP AG. All rights reserved. 24Confidential
Persistence LayerPersistence Layer
Domain Object LayerDomain Object Layer
Configuration Services
Configuration Services
Maintenance Services
Maintenance Services
ProductionServices
ProductionServices
ItemItem BOMBOM Work OrderWork Order RoutingRouting
DatabaseDatabase
WIPWIP ODSODS
PluginsPlugins
External View for Extending ME Application
UI Technologies• Adobe Flex• MS .Net/VB• HTML/JS
UI Technologies• Adobe Flex• MS .Net/VB• HTML/JS
Mobile Technologies• Smart Phones• Handhelds• HTML/JS
Mobile Technologies• Smart Phones• Handhelds• HTML/JS
Machine Integration• Pco• Vendor Specific• Message Bus
Machine Integration• Pco• Vendor Specific• Message Bus
© 2011 SAP AG. All rights reserved. 25Confidential
WIPQualityTraceabiliyData
CollectionECO
SAP Manufacturing Execution
• Java
• Web Services
Manufacturing API
Web Based ME Operator UI - Complex
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Example Operator UI with Adobe Flex
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Example UI on Android with Camera Scanner
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Producti Deployment Process
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Core ME application provided through Service Marketplace
Extensions can be provided by multiple sources
� 3rd Party Extensions
� SAP custom development
� Customer internal development
Overview
Performance/Scalability
Extensibility
Agenda
© 2011 SAP AG. All rights reserved. 30Confidential
Extensibility
Integration
Q&A
SAP Plant Connectivity (PCo)SAP Plant Connectivity (PCo)
SAP Plant Connectivity (PCo) for Equipment Integration
DashboardHistorian
Scada
Machine
MEMII
SAP ERP
Agent Destination
© 2011 SAP AG. All rights reserved. 31Confidential
LIMS
Alerts, etc.� Based on newest .NET Technology.
� High availability through implementation at machine level, data buffering, and retry
� Designed for high-performance, bi-directional communication
� Processing of alarms and events
� „Standard“-connectors from SAP
� Software Development Kit for partners/customers to develop own connectors
ERP Integration Architecture
Web Service
IDOC
ERPMII
Inbound
Web S
erv
icesTransformation
Workflow
Outbound
ME
© 2011 SAP AG. All rights reserved. 32Confidential
Web Service
BAPI/RFC
Web Service
SAP JCO
Outbound
HandlerA
sync
SyncEve
nts
SAP ERP Integration
SAP Communication
� ERP to ME � IDOCs
� ME to ERP � RFCs/BAPIs
MII Integration
� Data Enrichment
© 2011 SAP AG. All rights reserved. 33Confidential
� Data Enrichment
� Transformation through XSLT
� Customer specific workflow provided by MII Business Process Editor
SAP Manufacturing Execution
� Integration Framework
� Web Services
� SOAP over HTTP
Example Integration FlowERP
MII
Release
demandConfirmation
Production
Order
Confirmation
Planned
Order
BackflushIssue/Receipt
Goods
Issue/Receipt
Queue
Message
Call
BAPI
Create Where
Used Records
Create Where
Used Records
FG ProductionFG ProductionOrderB#: <blank>
© 2011 SAP AG. All rights reserved. 34Confidential
MII
SAP ME
PCo
Order ReleaseOrder Release
And
Serial #s
Execute
Operation
Order
Completion
Complete
OperationArchive
Machine
SetupTest ResultsTest Results
/ Measures
Component
Assemble
Component
Collect
Data
CompSFG-Comp
B#: 24932
FG ProductionFG ProductionOrderB#: 59875
ERP
HR� User Master Record
PP� Production Order� Planned Order� Routing� Work Center� BOM� Serial Number
MM� Material Master� Inventory Staging� Inventory Reserve� Batch Managed� Classifications� Storage Location
PM� Equipment� Measurement Points� Scheduled Downtime� Maintenance Order� RMA Service Order QM
� CAPA Processes
Functional ME ERP Integration Features
© 2011 SAP AG. All rights reserved. 35Confidential
ME
Dashboards
SAPMEINTSAPMEINTMII
� Yield Confirmation� Order Backflush� WIP Scrap Confirmation� Component Consumption� Batch Numbers
� Unscheduled Downtime � Equipment Usag� Inventory Return� Inventory Scrap� Inventory Release
� RMA Order Complete� Quality Notifications
Overview
Performance/Scalability
Extensibility
Agenda
© 2011 SAP AG. All rights reserved. 36Confidential
Extensibility
Integration
Q&A
Thank You!
Peter BaljetVice President of Product DevelopmentManufacturing Execution
SAP Labs, LLC1001 Summit BoulevardAtlanta, GA 30319
T: +1 404-943-2082E: [email protected]
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