core manufacturing detailed
TRANSCRIPT
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Core Manufacturing
Arne MantheySAP AG
06/2010
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© SAP 2007 / Page 2
ERP
SFAC
MES
Shop Floor
Automation
Monolith ic Systems
MOM
Shop Floor
Automation
ERP
Distributed Functions
System Borders blur…
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Plant Maintenance
Equipment Qualification
Maintenance Orders Time Tickets
Component -
Consumption
Work Assignment
Tools
Plant Maintenance
Equipment Qualification
Maintenance Orders Time Tickets
Component -
Consumption
Work Assignment
Tools
Production Planning
Production Orders /
Process Orders (S88) Operations / Phases
Time Tickets
Material Consumptions
PI Sheet / Electronic
Work Instructions
Production Planning
Production Orders /
Process Orders (S88) Operations / Phases
Time Tickets
Material Consumptions
PI Sheet / Electronic
Work Instructions
Warehouse Mgmt.
Production Supply
Transportation Orders
Warehouse Mgmt.
Production Supply
Transportation Orders
© SAP 2007 / Page 3
Quality Mgmt. Inspection Tasks
Inspection Lots
Sample Management
Usage Decision
Test Results -Recording
Quality Mgmt. Inspection Tasks
Inspection Lots
Sample Management
Usage Decision
Test Results -Recording
SAP ERP Touchpoint Processes with
Manufacturing
E R P
E R P
WMWM
WMWM PMPM
PMPM QMQM
QMQMPP /PP /
PPPP--PIPI
PP /PP /
PPPP--PIPI
APO APO
PP/DSPP/DS
APO APO
PP/DSPP/DS
Human Resources Qualification Records
Human Resources Qualification Records
Materials Mgmt. Inventory Control
Goods Movement
Batch Information
Material -Reservations
Material -Characteristics
Purchasing
Tools
Materials Mgmt. Inventory Control
Goods Movement
Batch Information
Material -Reservations
Material -Characteristics
Purchasing
Tools
MMMM
MMMMFIFI COCO HRHR
HRHR
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© SAP 2007 / Page 4
Manufacturing Levels and Landscape
FIFI COCO
E R P / S C
M
E R P / S C
M
M O M
M O M
S F A C
S F A C
HRHR
HRHR WMWM
WMWM MMMM
MMMM PMPM
PMPM QMQM
QMQM APO APO
PP/DSPP/DS
APO APO
PP/DSPP/DS
~1s
~8h
PI Sheet /
Electronic
Work Instructions
PP /PP /
PPPP--PIPI
PP /PP /
PPPP--PIPI
SAP MII
SAP Templates
& Partner Content
Separate
Manufacturing
Systems(MES, LIMS, Maintenance)
Visipri se / SAP ME,
Werum, … )
Separate
Manufacturing
Systems(MES, LIMS, Maintenance)
Visipri se / SAP ME,
Werum, … )
DCS / PCS
DCS / PCS
OPC
Devices
Devices
Industrial Bus
…Weigh Scales Actors Meters
Data Historian
Data HistorianSCADA / HMI
SCADA / HMI
Enterprise Services BAPI / RFCProcessProcess
MessagesMessages
FunctionFunction
CallCallIDOCIDOC
PIPI--PCSPCS
ControlControl
RecipesRecipes
PCo SAP ODA
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SAP Solutions for Manufacturing Execution
low-automation,
low-complexity,
central
high-automation,
high-complexity,
stand-alone
Process
DiscreteME
( )
© SAP 2008 / Page 5
MII Content Shop floor transactions
Worker UI
MII Content
Shop floor transactions Worker UI
ERP/PP Electronic Work
Instructions
XSteps
OPC
ERP/PP-PI PI-Sheets
XSteps OPC
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© SAP 2007 / Page 6
Manufacturing Levels and Landscape
Using ERP Manufacturing only
FIFI COCO
E R P / S C M
E R P / S C M
S F A C
S F A C
HRHR
HRHR WMWM
WMWM MMMM
MMMM PMPM
PMPM QMQM
QMQM APO APO
PP/DSPP/DS
APO APO
PP/DSPP/DS
DCS / PCS
DCS / PCS
~1s
OPC
SAP ODA
Devices
Devices
PIPI--PCSPCS
Industrial Bus
PI Sheet /
Electronic
Work Instructions
PP /PP /
PPPP--PIPI
PP /PP /
PPPP--PIPI
A u t o m . P r o c e s s
M e s s a g e s
…Weigh Scales Actors Meters
Synchronous Data Transfer Asynchronous Data Transfer
ProcessProcess
MessagesMessages
ControlControl
RecipesRecipes
FunctionFunction
CallCall
M O M
M O M
~8h
Separate
Manufacturing
Systems(MES, LIMS, Maintenance)
Visipri se / SAP ME,
Werum, … )
Separate
Manufacturing
Systems(MES, LIMS, Maintenance)
Visipri se / SAP ME,
Werum, … )
Data Historian
Data HistorianSCADA / HMI
SCADA / HMI
MII
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Manufacturing Levels and Landscape
PP / PP-PI
FIFI COCO E R P / S C M
E R P / S C M
S
F A C
S
F A C
HRHRHRHR WMWMWMWM MMMMMMMM PMPMPMPM QMQMQMQM APO APOPP/DSPP/DS APO APOPP/DSPP/DS
DCS / PCSDCS / PCS
OPC
SAP ODA
DevicesDevices
PIPI--PCSPCS
Industrial Bus
PI Sheet /Electronic
Work Instructions
PP /PP /
PPPP--PIPI
PP /PP /
PPPP--PIPI
A u t o m . P r o c
e s s
M e s s a g e s
…Weigh Scales Actors Meters
Synchronous Data Transfer Asynchronous Data Transfer
ProcessProcess
MessagesMessages
ControlControl
RecipesRecipes
FunctionFunction
CallCall
M O M
M O M
Third PartySystems(MES, LIMS, Maintenance)
Visipri se, Werum, …
Third PartySystems(MES, LIMS, Maintenance)
Visipri se, Werum, …
Data HistorianData HistorianSCADA / HMISCADA / HMI
Transaction DataMaster Data
XStepRepository Routing / Recipe Production / Process Order
BOMXSteps
Header
Operations
/ Phases
BOMXSteps
Header
Operations
/ Phases
Standard
XSteps
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PP /PP /
PPPP--PIPI
PP /PP /
PPPP--PIPI
© SAP 2007 / Page 8
PP / PP-PI:
XSteps, Master and Transaction Data
Transaction DataMaster Data
Order
Work Centers
/ Resources
Materials
(MM)
XStep
Repository
Routing / Recipe
+
+
+
BOMXSteps
Header
Operations
/ Phases
+
++
+
+
BOMXSteps
Header
Operations
/ Phases
+
+
+
+
+
Control Recipes
Electronic Work Instructions / PI Sheets
Documents
(Cross)
Equipments
(PM)
P P
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Header with order information
Containers for Operations / Phases(can be collapsed)
Instruction containers for convenient
structuring
Long text elements are on the left side
Short text and input elements are on the rightside
Tables stretch over the whole width
Repeated data input (extendable with new lines)
Grouped elements with similar structure
(e.g. check lists, generated material lists, …)
Scrollable
Input history can be logged
Comments can be entered at any time
© SAP 2007 / Page 9
Features of the PI Sheet / Electronic Work
Instruction (I)
PI Sheet - Change
Process order : 000123456 Material Number 10001234 >>
Change -> Display Save Complete Print Create Comment
Phase 0010
Goods receipt
Weighing
Preparation:
• Enter production date
• Enter tare weight of pallet
• Enter average weight of pieces
Weighing
• Put bin on the weigh scale
• Get bin weight
• Check result and confirm (OK?)
Sign the goods receipt
Production Date 08.06.2006
Tare weight of bins [kg] 1.000
Avg. piece weight [mg] 200.0
Signature
Total of pieces 21000
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Output of text instructions
In- and output of valuesDefault values, value validation
Tables
Calculations
Function calls
OPC data access(e.g. read measurement from device)
Digital signature (simple, multiple)
Automatic generation of order-related object(e.g. documents, components,…)
Event-triggered execution of commands and functions Automatic execution of functions (e.g. immediate check of material status)
Activation/deactivation of instructions based on conditions
Process messages
(Activity reporting, material consumption/production,…)
© SAP 2007 / Page 10
Features of the PI Sheet / Electronic Work
Instruction (II)
Tablet weighing
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XStep Life Cycle (I)
SXS Repository Routing/Recipe Order
© SAP 2007 / Page 11
SXS Repository
XStep Section o f Routing
XStep Section of Produc tion Order
SXS with parameters
Generated elements
(3 material components
assigned to the order)
Parameter values related to a specific component
Automatic valuation
of parameters
Routing-specific parameter values
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XStep Section of Product ion Order
Electronic Work Instruct ion (EWI)
XStep Life Cycle (II):
Order EWI/PI Sheet Process Message
© SAP 2007 / Page 12
Parameter values (Diameter Setup )
Line completed
PP_CONS Process Message
Material List in Production Order
Default value Deviation
Process message
books material
consumption
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Release History
Release Business Function Solution Characteristic Details
R/3 4.6c -HTML-based PI Sheet instructions(Big fon ts, images,…)
HTML formatting (Big fonts, images,…)
Flexible usage of custom function modules New generic process instruction (Type 0)
Electronic Batch Record (EBR)
R/3 4.7 -
Adapt iveness by usage of commands
and events
Easy OPC integration SAP ODA
R/3 4.7
Ext. 2.0- XSteps – Easy to reuse building blocks
ERP 2005
EhP2LOG_PP_PI_EHM
Process Industry Enhancements:
XSteps (regulated environment)
EhP3
LOG_PP_XS_RTG_PO XSteps for Routing and PO (Discrete)
LOG_PP_PMA_PMC Misc. PI Sheet enhancements
General styleheet enhancements
Discarding PI Sheets from process order
Mandatory entries by setting in characteristic
Improved PARAMETER_CHANGED event
New PDF printing function
Standard XStep L ibrary Collection of Standard XSteps:
SDN ( Downloads Core Manufacturing)
EhP5
(planned)
LOG_PP_PI_PMA_01 Archiving of PI Sheets and EWI
LOG_PP_XS_01 XStep enhancements for global izat ion Cross-plant repository
Language dependency
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Summary
PI Sheets / Electronic Work Instruct ions:
‚One-stop shop‘ for the worker to access and provide all ERP-relatedinformation. No need to run multiple transactions.
Flexibility and speed by dynamic and event-triggered instructions
Control of the material and information flow between ERP and production
systems (OPC)
XSteps: XSteps are easy to create and maintain. Much of the day-to-day work can be
done by functional departments. The IT department can concentrate on more
complex areas.
The repeated use of standard building blocks (SXS) reduces the maintenance
effort for the master data definitionInformation and XStep examples are available on:
BPX Community for Manufacturing
XStep Café
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Thank you!
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Title
MDA & OPC
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Interfaces with factory floor systems:
PI-PCS vs. OPC
PI-PCS Interface SAP OPC Data Access Message based
Targets fully automated processes
without user interaction
Asynchronous
Subscription
Vendors have to implementinterface;
Certification of solutions
Manual or semiautomatedprocesses with user interaction
(e.g. PI-sheet)
Synchronous
Industry standard is used;
no certification necessary
Generic
(any OPC DA Server)
Both interfaces complement each other !
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What is OPC?
” OPC is open connectivity via open standards”Source: OPC Foundation
Non-proprietary Industry-Standard
Non-profit Organization
Nearly 400 Members
www.opcfoundation.org
OPC St d d ff d b SAP ERP
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OPC Standards offered by SAP ERP
OPC Data Access (OPC DA)
OPC Events & Alarms (OPC EA)
OPC for Batch
OPC DX
OPC Data Historian
OPC XML
Security
OPC I t f i SAP ERP
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OPC Interface in SAP ERP
Manufacturing Operations
COM
SAP ERP: PP-PI
PI Sheet / EWI
SAP OPC: ODA Data Access OAE Alarms & Events
Local PC
SAP ODA Connector
(OPC Client)
OPC Server
RFC
Field
Local PC
SAP ODA Connector
(OPC Client)
OPC Server
R-01
Field
COM
AutomaticProcess
Messages
Download the SAP ODA Connector:
http://service.sap.com/manufacturing Downloads SAP OPC Data Access
Titl
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Title
EhP2:Enh. for Regulated
Industries
U f St d d XSt i R l t d
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Usage of Standard XSteps in a Regulated
Environment
Standard XSteps as Building Blocks for PI Sheets require additional features
(regulated environment):
Main features:
Approval procedure for SXS versions using digital signatures
Where-used list for SXS
XML export and import of folders, SXS and SXS versions
„Nice to have“:
Checksum test during XML import
Automatic numbering of SXS version
Automatic calculation of the valid to-date for released SXS version
Setup: Customizing [CMX21]
A l t t h f SXS i
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Approval status scheme for SXS versions
A l t t h f SXS i
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Approval status scheme for SXS versions
Wh d Li t f St d d XSt
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Where-used List for Standard XSteps
Title
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© SAP 2007 / Page 26
Title
EhP3:Misc. Enhancements
Overview
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Overview
Detail Functions
General styleheet enhancements
Discarding PI Sheets from process order
Mandatory entries by setting in characteristic
Improved PARAMETER_CHANGED event New PDF printing function
Customizing:
For all functions except discarding PI Sheets from process order
SPRO PP-PI Process Management Control Recipes Activate
Enhancements for PI Sheet
New Features and Functions
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New Features and Functions
Set fields mandatory with the
help of characteristics (flag
‚Entry Required‘ set )
Show comment icon in table cells
Enhanced New SAP Style Sheet
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Enhanced New SAP Style Sheet
LED Green: Signature completed
LED Yellow: Signature in progress
with more than one signer
LED Grey: Signature present, not
started yet
No LED: No Signature present
LED Green: Signature completed
LED Yellow: Signature in progress
with more than one signer
LED Grey: Signature present, not
started yet
No LED: No Signature present
LED Green: Signature completed
LED Yellow: Signature in progress
with more than one signer
LED Grey: Signature present, not
started yet
No LED: No Signature present
Icon Deactivated: Phase contains
deactivated elements
Icon Locked: Phase contains
locked elements
Icon Deactivated: Phase contains
deactivated elements
Icon Locked: Phase contains
locked elements
Icon Deactivated: Phase contains
deactivated elements
Icon Locked: Phase contains
locked elements
Icon for Signatures already done:
There are signatures present
Icon for Deviations: Deviations
occurred in the phase
Icon for Comments: Comments
were created for the phase
Icon for Signatures already done:
There are signatures present
Icon for Deviations: Deviations
occurred in the phase
Icon for Comments: Comments
were created for the phase
Icon for Signatures already done:
There are signatures present
Icon for Deviations: Deviations
occurred in the phase
Icon for Comments: Comments
were created for the phase
Easy to Adopt New Monitoring Transactions
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Easy to Adopt – New Monitoring Transactions
New transactions for
Control Recipe Monitor (CO53XT)
Process Message Monitor (CO54XT)
Work List for PI Sheets/Work Instructions (CO60 & CO60XT)
Using configurable ALV_GRID_XT:
Adding additional columns modification-free (via BAdI implementation and
customer-defined append structure)
PDF Print Function
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PDF Print Function
Title
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© SAP 2007 / Page 32
Title
EhP3:SXS Library
SXS Library: Facts
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SXS Library: Facts
Purpose
Collection of best-practice building blocks
Speed-up of implementation
Required Functionality Release
Usage of XStep-based PI Sheets (PP-PI)Since R/3 4.70
Ext. 2.0
Importing of XStep folders Since ERP 2004
Usage of XSteps for production orders
(work instruction sheets)ERP 2005 EhP 3
Content of the SXS Library
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Content of the SXS Library
Structure of the SXS Library
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Structure of the SXS Library
Folders for different
categories of SXS
SXS
Every SXS has a separate
documentary instruction
(To be deleted for later use)
Sample instructions
demonstrate the usage
Simulation:
Displays a
preview ofthe SXS on
the right side
Example: Checklist
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Example: Checklist
Show the usage of
SXS references
inside the SXS
repository
Show how parameters can be
used to control the behaviour of
an SXS reference (e.g. color)
Example: Material List
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Example: Material List
SXS Repository
Process Order: XSteps
Process Order: Bill of Material
HTML code valuation
Generation
Scope
SXS reference
in process order
Simulated XSteps inprocess order
(including generation)
40 character
material short text
Example: CSS Adoption
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Example: CSS Adoption
HTML long text with CSS
manipulation code
Change the background color
of the phase container
Change the background color
of the PI Sheet
How to get the SXS Library from SDN/BPX
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How to get the SXS Library from SDN/BPX
Downloads Core Manufacturinghttps://www.sdn.sap.com/irj/sdn/bpx-manufacturing
Name of Download Item (ZIP file) Description
Flexible Building Blocks for Shop Floor Instruction Sheets -Basic Standard XStep Templates
Library of SXS wihich do not use any custom
characteristics or function modules
Flexible Building Blocks for Shop Floor Instruction Sheets - Advanced Standard XStep Templates
Library of SXS which use custom characteristics or function
modules. (To be created before importing the library)
Flexible Building Blocks for Shop Floor Instruction Sheets -Standard XStep Library
Both basic and advanced libraries
Title
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© SAP 2007 / Page 40
Title
Appendix
Manufacturing Levels and Landscape
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© SAP 2007 / Page 41
g p
FIFI COCO
E R P / S C
M
E R P / S C
M
M O M
M O M
S F A C
S F A C
HRHRHRHR WMWMWMWM MMMMMMMM PMPMPMPM QMQMQMQM APO APO
PP/DSPP/DS
APO APO
PP/DSPP/DS
SCADA / HMISCADA / HMI
DCS / PCSDCS / PCS
~1s
~8h
OPC
SAP ODAPCo
DevicesDevices
PIPI--PCSPCS
Enterprise Services
Industrial Bus
PI Sheet /
Electronic
Work Instructions
PP /PP /
PPPP--PIPI
PP /PP /
PPPP--PIPI
A u t o m . P r o c e s s
M e s s a g e s
…Weigh Scales Actors Meters
Mapping/S95
BAPI / RFC
Synchronous Data Transfer Asynchronous Data Transfer
SAP MII
ProcessProcess
MessagesMessages
ControlControl
RecipesRecipes
FunctionFunction
CallCall
XI/PI (opt .)XI/PI (opt .)
Visualization
Bus. Logic
D a t a S e r v i c e s
IDOCIDOC
SAP
Templates
& Partner
Content
Data HistorianData Historian
Separate
Manufacturing
Systems(MES, LIMS, Maintenance)
Visipri se / SAP ME,
Werum, … )
Separate
Manufacturing
Systems(MES, LIMS, Maintenance)
Visipri se / SAP ME,
Werum, … )
Connecting MII and PI Sheet /
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© SAP 2007 / Page 42
g
Electronic Work Instructions
FIFI COCO
E R P / S
C M
E R P / S
C M
M
O M
M
O M
HRHRHRHR WMWMWMWM MMMMMMMM PMPMPMPM QMQMQMQM APO APO
PP/DSPP/DS
APO APO
PP/DSPP/DS
PI Sheet / Electronic
Work Instructions
PP /PP /
PPPP--PIPI
PP /PP /
PPPP--PIPI
BAPI / RFC
Synchronous Data Transfer Asynchronous Data Transfer
ProcessProcess
MessagesMessages
ControlControl
RecipesRecipes
FunctionFunction
CallCall
SAP MII
D a t a S e
r v i c e s
Visualization
Bus. Logic
HTTP request
Iframe (HTML)HTML content
HTTP
Data from MII
Visualization Applet
(Grid)
Query
Function Calls
Query
Display Template
Copyright 2007 SAP AG
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py g
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