x-change 2007 user group conference ugan maistry wonderware shop floor to sap top floor using sap...
TRANSCRIPT
X-Change 2007 User Group Conference
Ugan Maistry
Wonderware Shop Floor to SAP Top Floor
using SAP xMII
2
Agenda
IntroductionIntroductionIntroductionIntroduction
Real Time Production ExecutionReal Time Production Execution
Real Time FinanceReal Time Finance
SAP xMII – an OE EnablerSAP xMII – an OE Enabler
SummarySummary
3
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
4
OE Application Examples
Performance ManagementDispatch of GoodsMaintenance Planning
Continuous ImprovementMaterial TrackingInventory Management
Operational SynchronisationProduction Planning
5
Traditional Approach to OE
Adding More Silo Applications – Replicating Data, Increasing Complexity and Increasing Costs
6
Introducing SAP xMII
The only Composite Application Platform for Mining & Manufacturing Operations
7
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
8
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
9
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
10
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
11
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
12
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
13
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
14
Production Execution PCA Demo
Live Demo
15
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
16
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
17
Real Time Business Intelligence
Finance EnterpriseManagement
ProductionManagement
Plant ResourceManagement
Manufacturing Resource Base
Real-Time Finance
Real-TimeAccounting/DPM
Measure Context Act
18
Real Time Finance
19
Real Time Finance
20
Real Time Finance
21
Real Time Finance
22
Real Time Finance
23
Real Time Finance
24
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
25
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
26
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
1
After batch execution, SAP xMII aggregates production performance data and automatically updates SAP ERP inventory
2
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
3
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
4
Plant Manager initiates corrective action to fix the quality problem and resolve exception before it becomes customer issue
5
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!
27
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
1
2
5
3
4
Example – Customer Response Time
28
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
4
29
Visualisation Capabilities
30
Visualisation Capabilities
31
Agenda
Introduction
SummarySummarySummarySummary
Real Time Production Execution
Real Time Finance
SAP xMII – as OE Enabler
32
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
33
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!
34
THANK YOUFor
Attending
Questions???
X-Change 2007User Group Conference
35
36
37
38
39
40
Please use these icons in your presentations
41
But Gartner Says …
Service Oriented Architecture (SOA)
Enabler for ERP to Real-time systems integrationProviding a realistic chance of attaining Operational Excellence
42
Enterprise
SAP NETWEAVER
Oth
er S
AP
Bu
s.
So
lu t
ion
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