sap manufacturing execution baljet day 2fm.sap.com/data/upload/files/sap manufacturing... · sap...

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


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


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


� Support Any Device or Manufacturing Equipment

Standards Based Integration Services

ME Software Development Kit

Overview


Extensibility

Agenda


Extensibility

Integration

Q&A

Plant Locations ERP Data CenterRegional Data Center

ME, MII System Landscape Models

MIIME


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


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


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


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


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


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


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


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


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


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


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


� 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


Overview


Extensibility

Agenda


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


� 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


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


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


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


WIPQualityTraceabiliyData

CollectionECO

SAP Manufacturing Execution

• Java

• Web Services

Manufacturing API

Web Based ME Operator UI - Complex


Example Operator UI with Adobe Flex


Example UI on Android with Camera Scanner


Producti Deployment Process


Core ME application provided through Service Marketplace

Extensions can be provided by multiple sources

� 3rd Party Extensions

� SAP custom development

� Customer internal development

Overview


Extensibility

Agenda


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


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


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


� 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>


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


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


Extensibility

Agenda


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]

No part of this publication may be reproduced or transmitted in any form or for any

purpose without the express permission of SAP AG. The information contained herein may be changed without prior notice.

Some software products marketed by SAP AG and its distributors contain

proprietary software components of other software vendors.

Microsoft, Windows, Excel, Outlook, and PowerPoint are registered trademarks of

Microsoft Corporation.

IBM, DB2, DB2 Universal Database, System i, System i5, System p, System p5, System x, System z, System z10, System z9, z10, z9, iSeries, pSeries, xSeries, zSeries, eServer, z/VM, z/OS, i5/OS, S/390, OS/390, OS/400, AS/400, S/390 Parallel Enterprise Server, PowerVM, Power Architecture, POWER6+, POWER6,

POWER5+, POWER5, POWER, OpenPower, PowerPC, BatchPipes,

© 2011 SAP AG. All rights reserved.

SAP, R/3, SAP NetWeaver, Duet, PartnerEdge, ByDesign, SAP BusinessObjects Explorer, StreamWork, and other SAP products and services mentioned herein as

well as their respective logos are trademarks or registered trademarks of SAP AG in Germany and other countries.

Business Objects and the Business Objects logo, BusinessObjects, Crystal Reports, Crystal Decisions, Web Intelligence, Xcelsius, and other Business Objects products and services mentioned herein as well as their respective logos are trademarks or registered trademarks of Business Objects Software Ltd. Business Objects is an SAP company.

Sybase and Adaptive Server, iAnywhere, Sybase 365, SQL Anywhere, and other

Sybase products and services mentioned herein as well as their respective logos


POWER5+, POWER5, POWER, OpenPower, PowerPC, BatchPipes, BladeCenter, System Storage, GPFS, HACMP, RETAIN, DB2 Connect, RACF, Redbooks, OS/2, Parallel Sysplex, MVS/ESA, AIX, Intelligent Miner, WebSphere, Netfinity, Tivoli and Informix are trademarks or registered trademarks of IBM Corporation.

Linux is the registered trademark of Linus Torvalds in the U.S. and other countries.

Adobe, the Adobe logo, Acrobat, PostScript, and Reader are either trademarks or registered trademarks of Adobe Systems Incorporated in the United States and/or other countries.

Oracle and Java are registered trademarks of Oracle and/or its affiliates.

UNIX, X/Open, OSF/1, and Motif are registered trademarks of the Open Group.

Citrix, ICA, Program Neighborhood, MetaFrame, WinFrame, VideoFrame, and MultiWin are trademarks or registered trademarks of Citrix Systems, Inc.

HTML, XML, XHTML and W3C are trademarks or registered trademarks of W3C®, World Wide Web Consortium, Massachusetts Institute of Technology.

Sybase products and services mentioned herein as well as their respective logos are trademarks or registered trademarks of Sybase, Inc. Sybase is an SAP company.

All other product and service names mentioned are the trademarks of their respective companies. Data contained in this document serves informational purposes only. National product specifications may vary.

The information in this document is proprietary to SAP. No part of this document may be reproduced, copied, or transmitted in any form or for any purpose without the express prior written permission of SAP AG.

© 2011 SAP AG. Alle Rechte vorbehalten.

Weitergabe und Vervielfältigung dieser Publikation oder von Teilen daraus sind,

zu welchem Zweck und in welcher Form auch immer, ohne die ausdrückliche schriftliche Genehmigung durch SAP AG nicht gestattet. In dieser Publikation enthaltene Informationen können ohne vorherige Ankündigung geändert werden.

Die von SAP AG oder deren Vertriebsfirmen angebotenen Softwareprodukte können Softwarekomponenten auch anderer Softwarehersteller enthalten.

Microsoft, Windows, Excel, Outlook, und PowerPoint sind eingetragene Marken der Microsoft Corporation.

IBM, DB2, DB2 Universal Database, System i, System i5, System p, System p5, System x, System z, System z10, System z9, z10, z9, iSeries, pSeries, xSeries, zSeries, eServer, z/VM, z/OS, i5/OS, S/390, OS/390, OS/400, AS/400, S/390

Parallel Enterprise Server, PowerVM, Power Architecture, POWER6+, POWER6,

HTML, XML, XHTML und W3C sind Marken oder eingetragene Marken des

W3C®, World Wide Web Consortium, Massachusetts Institute of Technology.

SAP, R/3, SAP NetWeaver, Duet, PartnerEdge, ByDesign, SAP BusinessObjects

Explorer, StreamWork und weitere im Text erwähnte SAP-Produkte und

-Dienstleistungen sowie die entsprechenden Logos sind Marken oder eingetragene Marken der SAP AG in Deutschland und anderen Ländern.

Business Objects und das Business-Objects-Logo, BusinessObjects, Crystal Reports, Crystal Decisions, Web Intelligence, Xcelsius und andere im Text erwähnte Business-Objects-Produkte und -Dienstleistungen sowie die entsprechenden Logos sind Marken oder eingetragene Marken der Business Objects Software Ltd. Business Objects ist ein Unternehmen der SAP AG.

Sybase und Adaptive Server, iAnywhere, Sybase 365, SQL Anywhere und


Parallel Enterprise Server, PowerVM, Power Architecture, POWER6+, POWER6, POWER5+, POWER5, POWER, OpenPower, PowerPC, BatchPipes, BladeCenter, System Storage, GPFS, HACMP, RETAIN, DB2 Connect, RACF, Redbooks, OS/2, Parallel Sysplex, MVS/ESA, AIX, Intelligent Miner, WebSphere, Netfinity, Tivoli und Informix sind Marken oder eingetragene Marken der IBM Corporation.

Linux ist eine eingetragene Marke von Linus Torvalds in den USA und anderen Ländern.

Adobe, das Adobe-Logo, Acrobat, PostScript und Reader sind Marken oder eingetragene Marken von Adobe Systems Incorporated in den USA und/oder anderen Ländern.

Oracle und Java sind eingetragene Marken von Oracle und/oder ihrer Tochtergesellschaften.

UNIX, X/Open, OSF/1 und Motif sind eingetragene Marken der Open Group.

Citrix, ICA, Program Neighborhood, MetaFrame, WinFrame, VideoFrame und MultiWin sind Marken oder eingetragene Marken von Citrix Systems, Inc.

Sybase und Adaptive Server, iAnywhere, Sybase 365, SQL Anywhere und weitere im Text erwähnte Sybase-Produkte und -Dienstleistungen sowie die entsprechenden Logos sind Marken oder eingetragene Marken der Sybase Inc. Sybase ist ein Unternehmen der SAP AG.

Alle anderen Namen von Produkten und Dienstleistungen sind Marken der jeweiligen Firmen. Die Angaben im Text sind unverbindlich und dienen lediglich zu Informationszwecken. Produkte können länderspezifische Unterschiede aufweisen.

Die in dieser Publikation enthaltene Information ist Eigentum der SAP. Weitergabe und Vervielfältigung dieser Publikation oder von Teilen daraus sind, zu welchem Zweck und in welcher Form auch immer, nur mit ausdrücklicher schriftlicher Genehmigung durch SAP AG gestattet.

sap manufacturing execution baljet day 2fm.sap.com/data/upload/files/sap manufacturing... · sap...

Documents