sap mii templates module libraries batch...

SAP MII Templates

Module LibrariesBatch Manufacturing

SAP Advanced Manufacturing SummitSeptember 17th, 2009

Jeremy GoodSAP MII Field EnablementASM Manufacturing

© SAP 2009 /

1. Introduction

2. SAP MII General Overview

3. Module Libraries

4. Batch Manufacturing

SAP MII TemplatesAgenda

© SAP 2009 /

SAP ManufacturingIntegration and Intelligence (MII)

SAP ERP, SAP SCM …

SAP NetWeaver

SAP MII – Infrastructure

SAP MII – Content

Shop floor systems

CompositesCompositesComposites

Inspection/equipment testing

Plant datacollection

RFID sensors,bar codes

Deviceintegration

Plant Historian HMI MES SCADA / DCS

Intelligence Integration Innovation

Shop floorintegration

Shop floor UI

Compositioncapabilities

© SAP 2009 /

Manufacturing Integration & Intelligence

Composition Environment

Data Services

Visualization

Business Logic Services

Quality Engine

KPIs / Metrics / Alerts

SAP Manufacturing PlatformDelivers Information and Process Integration

PLAN MAKE DELIVER

MAKE

Simplified Execution

Global Coordination

ERP SCM PLM

LIMS/ Inspection /Equipment Testing

MESSCADA / HMI

Plant DataCollection

Wireless IntegrationEnvironmentalBuilding Management

Plant Historian

Plant DB

DCS / PLCvia OPC

•Planned Orders•Bills of Material•Production & ProcessOrders•Material Inventory Levels•Inspection Lots Data•Master Recipes•Material Details•Batch Details•Resources & FunctionalLocations•Maintenance Work Order &Notification details•Material & Order Costs

SAP MII extracts datafrom SAP ERP andprovides real-timevisibility and distributionto Plant Floor Systems of:

•Production Confirmations•Process Messages•Material Receipts•Material Consumptions•Material transfers•Inspection results recording•Quality Notifications•Batch Characteristic recording•Work Orders & resultsrecording•Maintenance Notifications

SAP MII’s ability to performtransaction execution intoSAP also enables automated,plant-level creation of:

SAP MII Integration Landscape

© SAP 2009 /

© SAP 2009 /

SAP MII – Sample CustomersPresented Success Stories at Events

http://www.sdn.sap.com/irj/scn/manufacturing-tools

SAP xApp Manufacturing Integration and Intelligence (xMII) Templates

Module Libraries

http://www.sdn.sap.com/irj/scn


http://www.sdn.sap.com/irj/scn

Production Order Transformation – from BAPIto Interactive Web Page

© SAP 2009 /

MII Business Logic Layout Samples

© SAP 2009 /

BAPI_PRODORD_GET_LIST BAPI_MATERIAL_GETLIST

Additional Module Library UI Examples

© SAP 2009 /

Additional Resource Areas Available on SDN

https://wiki.sdn.sap.com/wiki/display/xMII/Main https://forums.sdn.sap.com/forum.jspa?forumID=237

© SAP 2009 /

https://wiki.sdn.sap.com/wiki/display/xMII/Main

https://forums.sdn.sap.com/forum.jspa?forumID=237

Additional Resource Areas Available on SDN

http://www.sdn.sap.com/irj/scn/articles-manufacturing-all http://www.sdn.sap.com/irj/scn/manufacturing-tools

© SAP 2009 /

http://www.sdn.sap.com/irj/scn/articles-manufacturing-all


Partner Certified Composite Applicationshttp://www.sap.com/ecosystem/customers/directories/SearchSolution.epx

NW-CA-MFG - SAP NetWeaver Composite Application - Manufacturing

© SAP 2009 /

http://www.sap.com/ecosystem/customers/directories/SearchSolution.epx

https://sap.emea.pgiconnect.com/p68146097/

Batch Manufacturing

Session Recording by Industry Business Unit Chemicals

https://sap.emea.pgiconnect.com/p68146097/

© SAP 2009 /

Disclaimer

“This presentation is a preliminary version and not subjectto your license agreement or any other agreement withSAP. This document contains only intended strategies,developments, and functionalities of the SAP® product andis not intended to be binding upon SAP to any particularcourse of business, product strategy, and/or development.Please note that this document is subject to change andmay be changed by SAP at any time without notice. SAPassumes no responsibility for errors or omissions in thisdocument.”

© SAP 2009 / © SAP 2009 / Page 16

SAP MII for Manufacturing ExecutionCustomer Example with System Overview

Batch System-------------------------------------------

Process Control System

PP-PI QM MM SD

SAP MII (with TH Templates)

Work Instructions(incl. Quality Management)

KPI Monitoring(Overall Equipment Effectiveness)

EBR (Electronic Batch Record)

Process Cockpit

LogisticsExecution

System

SAP LES

Inventory

Historian

IBC

Packaging

© SAP 2009 /

SAP MII Batch ManufacturingProject Overall Goal & Strategy

Shop Floor Process Control

Connectivity, SCADA, HMI

ManufacturingOperations

Automation

ManufacturingEnterpriseProcesses

Visibility & Execution

Coordination

STRATEGYExtend SAP MII tools with Best Practice templates for shop floor processes, content & user interfaces

To meet plant needs for a decoupled, plant-specific solution for manufacturing operations

To drive competitive advantage through integrated manufacturing enterprise + operations processes

Expand SAP Manufacturingwith a PLANT-SPECIFIC SOLUTION

Provide A DECOUPLED SOLUTION forMANUFACTURING OPERATIONS

© SAP 2009 /

Independent system foroff-line use with ERPProven, best practiceprocesses, functionalityand contentDelivered & implementedby manufacturing experts

Accelerated implementationwith out-of-the-box,preconfigured templates andimplementation guideEasy user training withapplication and userdocumentation

SAP MII Batch Manufacturing Benefits

Low EffortLow TCO Low RiskLean MES implementationFree-of-charge applicationtemplates and contentCentral data maintenanceavoiding data redundancySeamless integration with SAPERP and shop floor systems

„SMART“ MES APPROACHIntegrated manufacturing enterprise and plant operations solutions from 1 vendorIndependent, plant-specific systemLean approach supporting core manufacturing execution processesLeverage of existing investments (SAP and automation systems)Central data storage and maintenance in ERPUse of SAP MII pre-built, standards-compliant ERP and shop floor connectivityFree-of-charge, best practice, preconfigured templates and contentFull template and installation documentation

© SAP 2009 /

SAP MII Batch ManufacturingComplements SAP Manufacturing

Manufacturing InfrastructureManufacturing Infrastructure

Energy & Environmental ManagementEnergy & Environmental Management

Quality & ComplianceQuality & Compliance

Production Data CollectionProduction Data Collection

Exception ManagementException Management

Manufacturing Intelligence

CostingCosting

Process simulationProcess simulation

Manufacturing Scope

Asset ManagementAsset Management

Employee health & safetyEmployee health & safety

Prod

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Sequ

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Loca

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Res

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WorkInstructions

ProductionExecution

ProductionConfirmation

Loca

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istic

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Prod

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Inno

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Del

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Serv

ice

&R

epai

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ProductionInfrastructure

ProductionSupport

ManufacturingExecution

Supply Chain &Manufacturing

Planning

Manufacturing Collaboration

SAP MII Batch ManufacturingReal-time Manufacturing Analyticsand Intelligence (for Supervisor)Manufacturing Execution (for Operator)

© SAP 2009 /

SAP MII Batch Manufacturing



SAPBusiness

Suite(Coordination)

Manufacturing PlanningManufacturing CollaborationEnterprise Asset ManagementQuality ManagementEnvironment, Health & Safety ComplianceSite Logistics (Warehousing & Inventory Mgmt.)Manufacturing Reporting / Product Cost Accounting

Manufacturing IntegrationManufacturing Intelligence

SAP MII Batch Manufacturing TemplatesManufacturing Preparation, Documentation andPerformance Reporting (for Supervisor)Manufacturing Execution (for Operator)

- Predefined role-specific processes- User interfaces- Preconfigured content- Documentation (process, configuration, customizing)

SAP MII

(Visibility &Execution)

© SAP 2009 /

SAP Partner Landscape for Batch Manufacturing

SAP Business Suite(SCM, PP, PP-PI, IM/WM, QM…)



Inspection/Equipment Testing Weigh ScalesPlant Historian HMI PLC SCADA / DCSLIMS

AutomationShop Floor Systems

Partner MES Systems“Comprehensive MES

Solution”

Partner Scheduling &EAM Systems

Intelligence Integration Innovation

SAP NetWeaver Composition Environment

SAP Plant Connectivity (PCo)

Batch Manufacturing Templates

SAP MII“SMART, Best Practice

MES Solution”

© SAP 2009 /

SAP MII Batch Manufacturing Project:Contributing Parties and Responsibilities

IBU ChemicalsSAP Application Solution Mgmt

Manufacturing / MII

SpecificationDevelopmentTestingImplementation support

Predefined Best Practice Templates forSAP MII Batch Manufacturing –

role-specific processes, content,user interfaces, documentation

Development Partners

ScopingSpecification & documentationDevelopment & TestingGo-To-Market & Roll-outImplementation

Customers

Scope & Specification reviewTestingPiloting

„Implementation“Partners

TestingGo-To-Market & Roll-Out

SAP Industry Solution MgmtIBU CP

Project managementScoping & SpecificationTestingGo-to-Market / Roll-out

© SAP 2009 / © SAP 2009 / Page 23© SAP 2009 / Page 23

SAP MII Batch ManufacturingDevelopment Partners

Systec & Services is a full-services system integrator that offers a wide range ofproducts and services to the regulated and process industries.

Our focus is in production, MES and validation. As an SAP Services Partner, we offer pre-validated, pre-configured and complementary MES solutions based on SAP MII.

Trebing + Himstedt is implementation partner for the SAP Manufacturingsolutions SAP MII and ME. As partner with the highest number of realizedSAP MII projects in Europe, we offer special expertise in all process industries (projects e.g. at Johnson &Johnson, Bayer, Sika, Novartis, Roche). We provide add-on MII Best Practice solutions for KPI Monitoring,Machine and Production Data Acquisition and Quality Management.

CIBER is a pure-play international system integration consultancy and outsourcing providerwith superior value-priced services and reliable delivery for both private and governmentsector clients. We cover the whole scope of services for SAP products, from traditional ERP consultancy toinnovative SAP solutions like RFID, MII etc. As an SAP partner for SAP MII we look back to > 8 years ofSAP MII implementations around the globe and >1.200 trained SAP MII users.Customers like Krones AG, ZF Sachs AG, Kellogg´s, Agrana etc. count on CIBER´s expertise in SAP MII.

© SAP 2009 /

SAP MII Batch Manufacturing ScopePhase 1 Delivery

SAP Business Suite(SCM, PP, PP-PI, IM/WM, QM…)



SAP MII Batch Manufacturing Templates

Automation Shop Floor Systems

ManufacturingOrder List

MaterialIdentification

Manufacturing Operations Cockpit

Shift BookWorkInstructions

Monitoring &LoggingQuality Control

ProductionConfirmation

Work Preparation Work Execution Documentation Performance

Weigh ScalesPlant Historian HMI PLC SCADA / DCSLIMSInspection/

Equipment Testing

ManufacturingPerformance

© SAP 2009 /

All Templates will have a Consistent StyleStyleguide UI Mockups

© SAP 2009 /

Manufacturing Operations Cockpit

Predefined RolesProduction supervisorShift supervisorShop floor operator

Role-specific Cockpit ContentNavigation tree

Links to applicationsCanvas Area

Central application(i.e. order list, shift book)Important Key Performance Indicators (i.e. yield, machine performance) with drilldown capabilitiesLinks to websites (i.e. MSDS Database)

Preconfigured, role-specific cockpits support efficient plant operations with real-timeinsight into activities and KPIs, as well as quick access to applications and data

Example: Operator Cockpit (N.B. No alerts in project phase 1 delivery)

© SAP 2009 /

Manufacturing Order List

User-friendly work list of scheduled process orders and important order details toprovide the overview at a glance and support efficient order selection and processing

SAP Business Suite (PP, PP-PI)

Process ordersControl recipes

Process Order Overview List / Selection ScreenProcess order numberPlantMaterial number (of material to be manufactured)Material short textScheduled start dateScheduled end dateResourceProcess order status

Follow-up activitiesMaterial identificationExecution of Work Instructions

Example of a similar Production Order List

SAP MII Batch Manufacturing – Manufacturing Order List

© SAP 2009 /

Material List Info.Process order numberMaterial numberMaterial short textIdentification statusBatch numberReservation numberQuantityUnit of Measure

Scanned BarCode Info.

Material numberBatch number(Reservationnumber)

(Process ordernumber)

Material Identification

Automated, handheld and barcode-supported material identification withcompleteness/correctness checking

Process Order List

SelectProcess

Order

DisplayManufacturing

Order List

DisplayMaterial

List

Scan Barcodes& CheckMaterial

Correctness

Confirm &Post Results

SAP Business Suite (PP, PP-PI)

Process orders(with material list)

Process messages(User, date/time, scanned data,& process order forElectronic Batch Record)

Complete materialidentificationCancel materialidentification

SystemCheck

SAP MII Batch Manufacturing - Material Identification

© SAP 2009 /

Work Instructions



Work instructions integrate manufacturing enterprise, operations and device data toprovide comprehensive task and process control, as well as documentation

SAP Business Suite (PP, PP-PI, QM)

Process ordersControl recipesInspection lots

Process messages(for Electronic Batch Record,process order, goods issue/receipt,order settlement)

Safety instructionsDisplay of text, documents, hazard symbols, MSDS

Material identificationSupport of manual, visual, barcode identification

Work instructionsWork instructions and data entry with automaticdata validation

In-process quality controlInspection result entry

Process order confirmation> All with digital signature and message support

SAP MIIBatch Mfg.

Work Instructions

© SAP 2009 /

SAP MII

PP-PI QMProcess Order

Work Instruction

Process OrderSelection

Order List

Control Recipe

Order Queue

Inspection Lot

InspectionCharacteristics

Confirmation

ConfirmationQuality Data

Manual InputElectronic Signature

RFCRFCIDOCIDOC

Example Work Instruction SheetProcess & Data Flow



Automation

© SAP 2009 /

Quality Control

Automation

SAP Business Suite (Quality Management)

Inspection lotInspection dataBatch number

Quality analysisSupport of single lot & cross-lot analysisStatistical Process Control (SPC)

Inspection result and defect recordingManual entry & data integration from LIMS / devicesQuantitative & qualitative result typesAutomatic tolerance validationDefect code notificationsDigital signature

Generation of new inspection pointsand physical samples



SAP MII Batch Manufacturing – Quality Control

Convenient application for shop floor quality control, integrating SAP ERP QualityManagement, LIMS and device data for efficient result recording and analysis

Inspection pointsPhysical samplesQuality notifications

Weigh ScalesPlant Historian HMI PLC SCADA / DCSLIMSInspection/

Equipment Testing

© SAP 2009 /

Production Confirmation

A straight forward application for production confirmation of process orders withautomatic plausibility and tolerance checking

SAP Business Suite(PP, PP-PI, MM)

Process order dataConfirmation data(for process order,goods issue/receipt)

Start / end date & timesActual quantities for consumed &produced materials(with automatic system checking)

Partial / final confirmationBatch numberComments (i.e. for exceptions)

SAP MII Batch MfgProduction Confirmation(Based on process order headerFor processing without Electronic Work Instructions)

Example: Production Confirmation

© SAP 2009 /

Shift Book

Shift Master Data MaintenanceTo set-up shift structure

Factories, shift workers, start date, messagesShift Instructions

To provide shift-relevant instructionsand information to shop floor operators

– Tasks, due date and times

Shift NotesTo document important productionmessages and events

Shift Hand-over ReportTo summarize production status &shift activities

– Current production, resource and order status– Shift messages and instructions

Easy-to-use shift book applications support accurate shift set-up, as well ascomprehensive management and reporting of shift activities, information, and events

© SAP 2009 /

Monitoring and Logging

Automatic capturing and logging of all relevant activities in SAP MII BatchManufacturing applications to support error detection and root-cause analysis

Log FileAutomatic logging and saving of system, as well as user actions

– Log parameters: Application, transaction, user, time, message, object, severity. etc.

Log MonitorLog message selection/retrieval to track and trace system and user actions

© SAP 2009 /

Manufacturing Performance

Comprehensive reporting and key performance indicator (KPI) tracking to supporttimely problem detection and efficient root-cause analysis

KPI Watch ListRole-based KPI views(Production supervisor, shift supervisor, operator)

Predefined calculations and data points

– Plant on-time delivery, production plan adherance– Production performance, quality, throughput, etc.– Energy used, energy intensity

Flexible KPI selection(time-frame, resource, cost center)

Traffic light status reporting

Drill down capabilities

List and graphical display (line, bar, gauge charts)

Production ReportProduction summary and process order list

© SAP 2009 /

Project Deliverables

SAP MII Batch Manufacturing Pre-configured TemplatesFor 9 application areas: From Manufacturing Cockpit to Manufacturing PerformanceDelivered via SAP Service Marketplace

Full DocumentationImplementation GuideApplication DescriptionUser Guide

Sales and Marketing AssetsFor customer use

Customer presentationSolution BriefOff-line demoBPX Wiki and Roundtable

For SAP employees and partner useFAQQuick sales guideDemo script (end Q4)

© SAP 2009 /

Technical Requirementsfor SAP MII Batch Manufacturing Implementation

SOFTWARESAP ERP: Release > R/3 4.7

Manufacturing set-up:– Production Planning – Process Industries (PP-PI),– Quality management (QM)– Materials Management (MM)– Plant Maintenance (PM)

SAP MII: Upgrade to Release 12.1SAP NetWeaver Composition Environment (NW CE): Release 7.1– With full content mgmt, life-cycle mgmtStandard database for SAP NetWeaver

HARDWAREMinimum 4 GB; recommended 8GB for productive system (= standard SAP MII requirements)

OPERATING SYSTEM64 Bit Windows Server

DATABASE For Best Practice ProcessesMicrosoft SQL 2005 (for first release only - thereafter support of multiple databases)

© SAP 2009 /

Target CustomersNext Step to Recruit Potential Pilot Customers

© SAP 2009 / Page 38

Pilot CustomersTimeframe – October 2009 – March 2010Industries - Chemicals and Consumer ProductsCustomer Profile - SAP customers with SAP ERP Manufacturing + SAP MII implementations

Prospects / CustomersTimeframe – With template general availability beginning Q4 2009Industries - All Batch Manufacturing Industries

Priority focus: Chemicals and Consumer ProductsSecondary focus: Life Science, Oil & Gas (i.e. Lubricants), Mill (i.e Metals), High Tech

Customer Profile – Customers/Prospects needing lean, manufacturing executionSAP LE customers & prospects – For new plants; legacy replacementSAP ME customers & prospects – All plants with manual processes, & new plants

Geography – First phase: US, EMEA Mature (DACH + Benelux), APJ

© SAP 2009 /

Key Learnings and Next Steps

Delivers preconfigured templates, content and documentation for SAP MII

Will support manufacturing execution in batch manufacturing industries

Templates will be delivered free of charge to customers and partnersDownloadable from SAP Service MarketplaceAvailable for all customers with a software license for SAP MIIAvailable for all partners with a demo license for SAP MII

Templates can be used withSAP ERP: Release > R/3 4.7SAP MII: Release 12.1

Implementation partners are required for global roll-out and“Best-Run” packagesExtension of customer implementation projects: ERP + Manufacturing OperationsDevelopment partners are available for implementation project support

Recruitement for pilot customers is in processApproach your SAP MII customers and prospects

Sales assets and virtual solution training sessions coming mid-end OctoberInterested partners to contact [email protected]

SAP MII Batch Manufacturing…

mailto:[email protected]

Thank you!

© SAP 2009 /

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