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Ugan Maistry Wonderware Shop Floor to SAP Top Floor using SAP xMII

Ugan Maistry Wonderware Shop Floor to SAP Top Floor using SAP xMII. Introduction. Real Time Production Execution. Real Time Finance. Agenda. SAP xMII – an OE Enabler. Summary. Introducing Operational Excellence. OE is the … Joint/Mutual Achievement of: Performance Management

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Ugan Maistry Wonderware Shop Floor to SAP Top Floor using SAP xMII

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  1. Ugan Maistry Wonderware Shop Floor to SAP Top Floor using SAP xMII

  2. Introduction Real Time Production Execution Real Time Finance Agenda SAP xMII – an OE Enabler Summary

  3. Introducing Operational Excellence • OE is the … • Joint/Mutual Achievement of: • Performance Management • Continuous Improvement • Operational Synchronisation • To optimise production, business processes and product quality enterprise wide • With the aim of … • Reducing response times – time to market • Adapting flexibly to market conditions • Successfully implementing strategic decisions

  4. OE Application Examples • Performance Management • Dispatch of Goods • Maintenance Planning • Continuous Improvement • Material Tracking • Inventory Management • Operational Synchronisation • Production 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. Adaptive Manufacturing Manufacturing Operations SAP Manufacturing (mySAP ERP) 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 SAP xMII Manufacturing Integration Manufacturing Intelligence Composite Application Platform

  8. SAP and Invensys • Invensys achieved SAP certification last year • SAP and Invensys undertaken co-innovation programme • Build on SAP NetWeaver and Invensys ArchestrA as SOA’s • Design and build Packaged Composite Applications (PCA’s) • That add real value in attaining Operational Excellence

  9. Financial Reporting Real Time Production Execution Real Time Finance Targeted Areas of Co-Innovation CEO Business Measurement Business Operation COO CFO Enterprise Management Monthly Real-Time Finance Production Management Daily Real-Time Accounting/DPM Plant Resource Management Real-Time Manufacturing Resource Base

  10. Introduction Real Time Production Execution Real Time Finance Agenda SAP xMII – an OE Enabler Summary

  11. SAP EP PP/PI MM QM PM BW Real Time Production Execution PCA PCA (xApp) Combines SAP xMII + Wonderware’s Production & Performance Management software to deliver sustainable value “Out of the Box” ERP SAP NetWeaver My SAP 2005 XI RFC/IDOC Man Services Man Services Enterprise • Composition • SAP xMII, Wonderware System Platform + Modules • Load PCA to xMII • Load PCA to Wonderware • Configure Equipment Site SAP Control Recipe/Sched Logic xMII Production Interface “Out of the Box” Production Work Order Handling Logic Production Status/ Alert Management Prod Work Order dispatching Service Production Status/ Alert Service • 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 Operations DB/ Services Product Deviation Management Equipment Setup Management Production Performance Production WorkOrder Tracking Production Operation Execution Data Collection Existing Process Control / Machine Control

  12. 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 Real Time Production Order Creation

  13. 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 Real Time Production Execution

  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. Introduction Real Time Production Execution Real Time Finance Agenda SAP xMII – an OE Enabler Summary

  17. Cemex Balcones Plant Real Time Business Intelligence Act Measure Context Enterprise Management Finance Real-Time Finance Production Management Real-Time Accounting/DPM Plant Resource Management Manufacturing Resource Base

  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 reporting • Real Time Accounting/DPM empowers plant floor personnel to behave in a manner that drive business value • Real Time Finance ties the management and executive level into the performance of all manufacturing and industrial assets in real time • Plant floor financials are calculated at the speed of the business and more closely represent the truth • Measuring correctly and in real time enables continuous business performance improvement

  25. Introduction Real Time Production Execution Real Time Finance Agenda SAP xMII – an OE Enabler Summary

  26. 1 Production schedule is sent from SAP ERP to SAP xMII, transmitted to the Manufacturing Operations Management System and displayed on Mfg. Dashboard SAP NETWEAVER SAP Manufacturing (mySAP ERP) Alert! After batch execution, SAP xMII aggregates production performance data and automatically updates SAP ERP inventory 2 Manufacturing Intelligence Dashboards SAP BI Other SAP Bus. Solu tions 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 SAP xMII Manufacturing Intelligence Manufacturing Integration Plant Manager initiates corrective action to fix the quality problem and resolve exception before it becomes customer issue 5 SAP xMII – Illustrative Scenario

  27. 4 Example – Customer Response Time • Look up customer PO from SAP & return SAP Production Order • Find Vehicle(s) created to satisfy Production Order 1 • Get Historian and LIMS data for vehicles, run xMII Analytics 2 3 • An SPC Alarm may point to a Vehicle production problem – providing an overview of Customers affected 5 • Decide what action: Email report to Product Manager, SMS alert….

  28. 1 2 4 5 Example – Metallurgical Accounting • Retrieve Assay results from LIMS system • Retrieve Dry/Wet Masses from Weighbridges, SCADA, DCS etc • Calculate Metal Content based on assay analysis and masses • Do SPC Analysis to determine variances and improve plant processes 3 • Update SAP with relevant data per process order

  29. Visualisation Capabilities

  30. Visualisation Capabilities

  31. Introduction Real Time Production Execution Real Time Finance Agenda SAP xMII – as OE Enabler Summary

  32. Summary • SAP and Wonderware utilising SOA for integration • Configurable (not bespoke) • Allowing the business the flexibility to change on demand • Increase agility while decreasing maintenance and development costs • PCA’s released are the first of many • Business 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. Questions??? X-Change 2007 User Group Conference THANK YOU For Attending

  35. Please use these icons in your presentations

  36. But Gartner Says … • Service Oriented Architecture (SOA) • Enabler for ERP to Real-time systems integration • Providing a realistic chance of attaining Operational Excellence

  37. Enterprise SAP NETWEAVER SAP Manufacturing (mySAP ERP) Manufacturing Intelligence Dashboards • Real-time events/alerts • Order status • Yields • Completions and usage • Start and stop times • Quality and lab data • Process history • Downtime tracking • Plan work orders • Check resources • Create mfg plan • Scheduling • Release work order • Close order • Shipping and logistics SAP BI Other SAP Bus. Solu tions SAP xMII Manufacturing Intelligence Manufacturing Integration Manufacturing Integration

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