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Performix Inc: Implementing MES in SAP Landscape

Performix Inc: Implementing MES in SAP Landscape. Implementing MES in SAP Landscape. Sham Afzalpurkar CEO, Performix Inc. September 26 th , 2006. Introduction. Sham Afzalpurkar, CEO Performix Inc About Performix A Manufacturing Execution Systems company Developing xApps in MES space

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Performix Inc: Implementing MES in SAP Landscape

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  1. Performix Inc: Implementing MES in SAP Landscape

  2. Implementing MES in SAP Landscape Sham Afzalpurkar CEO, Performix Inc. September 26th, 2006

  3. Introduction • Sham Afzalpurkar, CEO Performix Inc • About Performix • A Manufacturing Execution Systems company • Developing xApps in MES space • Significant Supply Chain, Manufacturing Execution &Track/Trace experience • Focus on Pharmaceuticals, Process Industries and Hi Tech • Offices in Houston, Texas with development teams in India

  4. Agenda • Overview of MES • Justifying MES • Developing MES Strategy • MES Architecture • Integration Strategy • Implementation Plan • Lessons Learned

  5. Why MES? • In the last decade, ERP and SCM have NOT delivered the expected returns • Focus on deploying MES solution to give visibility and flexibility and effectively manage supply chain • Competition has forced quality products at lower cost • Integration of ERP and MES has been a challenge • Standards such ISA 95 provide the potential to simplify deployment

  6. What is Manufacturing Execution System? • Co-ordinate functions on the shop floor to optimize the plant activities • Manufacturing Execution System provides effective integration between production processes and enterprise business systems. • Layer of communication between business and control systems ERP MES SHOP FOOR AUTOMATION

  7. Components of MES • Core • Material and Production Tracking • Material Handling and Production Procedures • Resource management and allocation • Production Dispatching • Data Collection • Extensions • Compliance • Quality Assurance • Performance Analysis • Detail Scheduling • Document Management • Labor Management

  8. What is ISA 95? • Instrumentation, Systems, and Automation Society (ISA) Standard • Standard that defines how to link Enterprise and Controls systems using a Manufacturing Execution Systems (MES) layer. This standard describes: • The MES Functionality • The Data base schema at the MES Level • The Messages between the Enterprise system and MES

  9. What is B2MML? • The World Batch Forum (WBF) has published XML schemas based on the S95 Model - B2MML (Business to Manufacturing Markup “Hypertext” Language) • B2MML-V0201-Common.xls • B2MML-V0201-Personnel.xls • B2MML-V0201-Equipment.xls • B2MML-V0201-Material.xls • B2MML-V0201-Maintenance.xls • B2MML-V0201-ProcessSegment.xls • B2MML-V0201-ProductionDefinition.xls • B2MML-V0201-ProductionCapability.xls • B2MML-V0201-ProducitonPerformance.xls • B2MML-V0201-ProductionSchedule.xls

  10. MES vendors offer solutions that overlap functionality offered by SAP

  11. Agenda • Overview of MES • Justifying MES • Developing MES Strategy • MES Architecture • Integration Strategy • Implementation Plan • Lessons Learned

  12. Justifying MES – Business Drivers • Visibility of data globally • Standard processes • Enable benchmarking and best practices • Consistent Documentation • Resource Utilization • Accurate and consistent KPI • Seamless Integration

  13. Justifying MES - Benefits • Increases Operational Excellence • Lower Operating Costs • Asset Management • Reduced Total Cost of Ownership

  14. Agenda • Overview of MES • Justifying MES • Developing MES Strategy • MES Architecture • Integration Strategy • Implementation Plan • Lessons Learned

  15. Manufacturing Assessment & Planning • What are the business drivers? • What are the organizational and process related issues? • What should be done first – aligning manufacturing strategy with business strategy

  16. Business Functions (S95) Enterprise Performance Reporting Level 4 Business Planning & Logistics Demand Planning Supply Chain Planning Cost Accounting Human Resource Management Sales & Distribution Material Management Production Planning Warehouse Management Maintenance Management Detail Scheduling Process Optimization Recipe Management Performance Management Process Analysis Level 3 Manufacturing Operations Resource Management Production Execution WIP Material Management Production History Quality Management Real-Time Execution Real-Time SPC Level 2 Plant Floor Control Real-Time Control Real-Time Monitoring

  17. ERP Enterprise Performance Reporting Demand Planning Supply Chain Planning Cost Accounting Human Resource Management Sales & Distribution Material Management Production Planning Warehouse Management Maintenance Management Detail Scheduling Performance Management Process Analysis Resource Management Production Execution WIP Material Management Production History Quality Management Some PLCs Machines & Work Centers Fixed Routes, No Lot Splitting Only Ingredients Changes Real-Time Execution Real-Time SPC Real-Time Control Real-Time Monitoring Simple Discrete

  18. ERP Enterprise Performance Reporting Demand Planning Supply Chain Planning Cost Accounting Human Resource Management Sales & Distribution Material Management Production Planning Warehouse Management Maintenance Management Detail Scheduling Process Analysis MES Thousands of parts, complex procedures, many products Resource Management Production Execution WIP Material Management Production History Quality Management Some PLCs Machines & Work Centers Production Lines Real-Time Execution Real-Time SPC Real-Time Control Real-Time Monitoring Aerospace and Automotive Complex Discrete

  19. ERP Enterprise Performance Reporting Demand Planning Supply Chain Planning Cost Accounting Human Resource Management Sales & Distribution Material Management Production Planning Warehouse Management Maintenance Management many shared resources, complex routing, many products MES thousands of parts, complex procedures Detail Scheduling Process Optimization Recipe Management Performance Management Process Analysis Resource Management Production Execution WIP Material Management Production History Quality Management Some PLCs Machines & Work Centers Production Lines Real-Time Execution Real-Time SPC Real-Time Control Real-Time Monitoring Semiconductor

  20. Pharmaceuticals & Specialty Chemicals ERP Enterprise Performance Reporting Demand Planning Supply Chain Planning Cost Accounting Human Resource Management Sales & Distribution Material Management Production Planning Warehouse Management Maintenance Management many shared resources, large recipes, many products MES compliance, complex procedures Detail Scheduling Process Optimization Recipe Management Performance Management Process Analysis Resource Management Production Execution WIP Material Management Production History Quality Management SCADA / PCS Equipment Trains Flexible Connections Real-Time Execution Real-Time SPC Real-Time Control Real-Time Monitoring

  21. Oil & Gas and Bulk Chemicals ERP Enterprise Performance Reporting Demand Planning Supply Chain Planning Cost Accounting Human Resource Management Sales & Distribution Material Management Production Planning Warehouse Management Maintenance Management SCADA / PCS Equipment Trains Fixed Connections Large number of control variables, real-time optimization Process Optimization Performance Management Process Analysis Production History Quality Management Real-Time Execution Real-Time SPC Real-Time Control Real-Time Monitoring

  22. MES Functionality • Dispatching and Production • Resource Allocation • Quality Management • Data Collection • Process Management • Production Tracking and Genealogy • Document Control • Performance Analysis • Operational Detail Scheduling

  23. Dispatching Production • Manages the flow of production in the form of jobs, orders, batches, lots and work orders by dispatching production to specific equipment and personnel. Includes information that is presented in the sequence in which the work needs to be done.

  24. Resource Allocation & Status • Manage the resources directly associated with control and manufacturing.

  25. Data Collection & Acquisition Obtains operational production and parametric data associated with production equipment and processes. Provides real-time statuses of production equipment and processes.

  26. Quality Management • Provides real-time measurements collected form manufacturing to assure proper product quality control and to identify problems requiring attention. Includes SPC / SQC tracking and management of offline inspection operations .

  27. Process Management • Monitors production and either automatically corrects or provides decision support to operators for correcting and improving in-process functions. It may include alarm management to handle process deviations.

  28. Production Tracking & Genealogy • Provides status of production and disposition of work. Status information may include personnel, materials used, current production conditions. Includes recording of production information to allow forward and backward traceability.

  29. Performance Analysis • Provides real-time reporting of actual manufacturing operations results along with comparisons to past history and expected results. Performance results include resource utilization, resource availability, cycle time, conformance to schedule and standards. May include SPC / SQC analysis

  30. Operations & Detailed Scheduling • Provides sequencing based on priorities, attributes, characteristics and production rules. It is finite and it recognizes alternative and overlapping operations to calculate timing of equipment loading

  31. Document Control • Control records and forms that must be maintained with the production unit. Includes work instructions, recipes, drawings, standard operating procedures (SOP), batch records, shift to shift communication. It sends instructions down to operations and device controls

  32. Labor Management Provides status of personnel. Includes time and attendance, certification tracking, as well as preparation work as basis for activity–based costing. May interact with resource allocation for optimal assignments.

  33. Maintenance Management • Functionality for maintaining equipment and tools. Ensures equipment and tools availability for manufacturing. May also include scheduling for periodic or preventive maintenance. Maintains history of past events to aid in diagnosing problems.

  34. Agenda • Overview of MES • Justifying MES • Developing MES Strategy • MES Architecture • Integration Strategy • Implementation Plan • Lessons Learned

  35. SAP MES Architecture APO Demand Planning SNP PPDS Global ATP SAP R/3 BW Plant Maintenance Materials Management Production Planning Quality Management Human Resources xMII Integration Intelligence Dashboard S95 Master & Transaction Data xApps/Composite Apps MES OPC LIMS Historian PAT SCADA Devices Doc Mgmt

  36. Agenda • Overview of MES • Justifying MES • Developing MES Strategy • MES Architecture • Integration Strategy • Implementation Plan • Lessons Learned

  37. SAP MES Integration Options • Use SAP xMII – Preferred • Build your own XI integration

  38. Enterprise SAP NETWEAVER SAP Manufacturing (mySAP ERP) Manufacturing Intelligence Dashboards SAP BI Other SAP Bus. Solu tions XI SAP xMII Manufacturing Intelligence Manufacturing Integration Plant Floor SAP MES Integration Using xMII • SAP xMII enables real-time transactional integration between plant floor and enterprise (SAP ERP) systems out-of-the box thru: • Universal Connectivityto the data, functionality and processes of existing plant floor systems and SAP • Advanced composite application capabilitiesfor creating automated events, KPIs and alerts, and new manufacturing business processes • Synchronization of SAP ERP with real-time Plant Floor Systems and Processesusing proprietary and standards-compliant messages and workflows • Data Services that provide a foundation for Manufacturing Synchronization and Intelligence

  39. Shopfloor Application – ANSI/ISA-95 Compliance B2MML Msg SAP R/3, SCM, BW… MES Integration with SAP – Using xMII PEOPLE SAP Enterprise Portal INFORMATION SAP xMII Integration Use xMII Integration capabilities if S95 Non Compliant = SAP = 3rd Party Application

  40. Agenda • Overview of MES • Justifying MES • Developing MES Strategy • MES Architecture • Integration Strategy • Implementation Plan • Lessons Learned

  41. MES Deployment Strategy • Understand the problem you are trying to solve • The business drivers • How you deploy has impact on cost and scope • Integration with Process Control and other applications • Change in the business processes • Facility readiness

  42. Analyze manufacturing processes and develop MES requirements Map requirements with SAP Functionality. Assessment Map MES Requirements Detail plan for pilot and rollout Design MES Architecture Identify gaps Develop Deployment Plan Develop global processes, Integration touch points Pilot Roll Out Review Pilot results Start Ramp-up

  43. Why Pilot? • Enhance understanding of MES • Determine how well current requirements fit into an MES • Validate the Integration strategy

  44. Scope of Pilot • Should cover end to end processes • Team • Project Lead • SAP Expertise – MM/PP/PI, QM, APO • Automation Expertise • QA/QC • Integration/xMII • Plant Floor • Timeline • About 3-4 months

  45. Take Aways • There is an overlap of functionality offered by SAP and MES vendors • Perform detail MES requirement mapping with SAP functionality • Make the decision up front where the functionality resides (SAP or MES) • In many cases SAP + xMII + xApp could meet your requirements • For complex processes, compliance and regulatory requirements, consider third party MES solutions • xMII is the preferred Integration solution in the SAP landscape • Start with an end to end pilot

  46. 0707 Session Code:

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