speaker: klaus siegemund (ferrero) co-speaker: josé ...€¦ · • budgeting process integration...
TRANSCRIPT
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01.12.2015 Page 1
Speaker: Klaus Siegemund (Ferrero)
Co-Speaker: José Iglesias (Ciber)
Oktober 2015
at
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01.12.2015 Page 2
Need for a 360° view on manufacturing
Source: SAP AG
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01.12.2015 Page 3
Users don´t care about systems and applications
Source: SAP AG
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01.12.2015 Page 4
Ferrero Group Facts
Start as a pastry shop in Alba (Italy, Piemont)
1946 Company founded in Italy by Michele Ferrero
Today global, non-listed company
Since its foundation in family ownership: CEO Giovanni Ferrero
The Ferrero Group in figures:
• ~ 30,000 employees
• 22 plants and 46 business units
• Turnover 2013: 8 Billion €
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Worldwide Plants
01.12.2015 Page 5
Irland
Belgien
Frankreich
Italy
(4 Plants)
Deutschland
Polen
Kanada
Kamerun
Südafrika
Ecuador
Argentinien Brasilien
Türkei
Indien
Sri Lanka
Australien
Russland
Mexiko
China
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German Plant Stadtallendorf
01.12.2015 Page 8
• First and largest production site of Ferrero outside Italy
• Workforce average of 4,000 employees
• Areal has size of 634,000 square meter in total
• High-Bay warehouse capacity for 70,000 pallets, expansion to 90,000 in 2016
• Worldwide Export
Gate
FG Warehouses
R/P Wh.
Power Plant
Chocolate
Factory
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Ferrero Brands
01.12.2015 Page 9
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01.12.2015 Page 12
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MII in Production and Quality Management
01.12.2015 Seite 13
Production Lines
QM IPC QualityControl
RealtimeMES
QMDashboard
Time Mgmt.
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Integrating Automatic Palletizer with MII
01.12.2015 Seite 14
Packing
Machine
Packing
Machine
Palletizer Applicator
PLC
Scanner
SAP
(ERP)MIIDB
MII Web Page
(display
on panel-PC)
Select
Order
Order +
Schema
WINCC
PCo
Show
Orders
Order
Details
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01.12.2015 Page 15
Demand to implement EM
As is situation
New Horizons
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How shall we begin ?
Simply define your requirements
01.12.2015 Page 16
Simple!
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SAP ERP Preventive Maintenance
Continuous Improvement
Hu
ma
n C
ap
ita
l
Org
an
iza
tio
n
Predictive Maintenance
Budget / Investments
Productive MaintenanceMES / SF*
OEE
Dashboard
Production Efficiency
Idea
Managem
ent
MobilitySAP BI
Operations
Energy Management
Energy Management is embedded
01.12.2015 Page 17
* Shop-Floor
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01.12.2015 Page 18
Main Intentions
• Increase energy efficiency in our group
• Comparison between production lines
• Tool for identifying potentials for savings
• Benchmarking our own energy improvements
• Overall Corporate Energy Balance
• Profitcenter responsability
• Compare historical periods
• Budgeting process integration
• Cost controlling - Energy cost per product / cost center
• Evidence of Green Production
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01.12.2015 Page 19
Expectations
• One central solution covering all functions
• Substitute EXCEL and other island solutions
• International standards and KPI
• Flexible business reports
• Dynamic report creation by user
• Minimum effort for configuration
• Good performance based on high data volume
• Stable and complete data transfer all over the chain
• Less data layers / interfaces
• High integration potential
• Open to OEE, Maintenance, Financial, Controlling
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01.12.2015 Page 20
Different Types of Measurements
• Primary– Electric Power (by Source)
– Gas
– Oil
– ……….
• Secondary– Compressed Air
– Steam
– Fresh Water (different temperatures)
– Waste Water
– ………..
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01.12.2015 Page 21
Demand to implement EM
As is situation
New Horizons
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Current Solution
01.12.2015 Page 22
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Landscape Shop-Floor (Germany)
01.12.2015 Page 23
SiemensWINCC
FrakoServer
non electricalPowerratefor WinCC
TransformerCounter
~ 800
FrakoServerFrako
Server
electrical
non counted kWhConcentrator (security level)
CompressedAir
Steam
Counter ~ 150
High Power Bus
operationalDatabase
SQL-Server
MII
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Landscape Shop-Floor
01.12.2015 Page 24
Acquisition
Systems
Sub system
Priv. Fieldbus
Acquisition
Devices
Ethernet/Field
-bus
PLC
Power Rate
Acquisition
Devices
ProfiNet / Ethernet
Ethernet/Field
-bus
EDMS Interface
Systems
Concentrator
Sub system
Transfer rate
15 min
PLC Power Rate
Up to 6 FIFO buffers for
one S7-300. Each buffer is able
to buffer 20 measuring points
for one day when the EDMS is
not available.
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Local Landscape
01.12.2015 Page 25
MII
MESEDMS
Siemens
WebserviceEC
EEMSOAP
XML
operationalDatabase
SQL-Server
Data accumulated15‘ base
BWU
Manual InputSAP ECCPP-PI
QLI
Pieces
Run- and Idle time
INFOCube
Webservice
PI
External
Local
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Global Landscape
01.12.2015 Page 26
From ECC
Central Instance
EC-EEM
Group System
Turkey
MES MII
Mexico
MII
ECC GEA
PI GEA
GER + ITA*
MES
MIIPI OHG
Local Plant Systems
ECC OHG From ECC
Local Instance
Operational
Database
SQL-Server
Operational
Database
SQL-Server
Historian MII
Operational
Database
SQL-Server
Operational
Database
SQL-Server
XI Proxy
MappingProd. Data
async
sync
Tag-listtagnames
tagnames
tagnames
GER Data
MEX Data
TUR Data
Propagate Tagnames
Back to other MIIand ECC
tagnames
Plant Data
Italy
Historian
*temporary
BI
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Example – Daily Energy Report
01.12.2015 Page 27
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Energy per 100 kg production output
01.12.2015 Page 28
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01.12.2015 Page 29
Demand to implement EM
As is situation
Open new horizons!
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Main Pillars approaching the future solution
01.12.2015 Seite 30
MII
on
HANA
HANANear
Real Time
Integration
Mobility
HTML 5
Easy
Analytics
Energy Management 2.0 = Energy2Go
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Current System Landscape Simplification
01.12.2015 Seite 31
Meter
0,000 Meter Data
Management
System
MES
PCOOPC
MII EM BI
SSCE
HANA
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System Landscape Simplification
01.12.2015 Seite 32
Meter
0,000 Meter Data
Management
System
MES
PCOOPC
MII EM BI
Meter
0,000 Meter Data
Management
System
MES
PCOOPC
MII
BI
SSCE*
*SSCE = Self Service Composition Environment
HANA
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HANA EM 2.0 – Reporting View
01.12.2015 Seite 33
HANA DB
Big
Data
High Performance availabiliity with MII 15.x
Custom
ApplicationsStandard - SW
Reporting on MII with SSCE
Services
Interfaces
Inte
gra
tion S
cenario
Office Integration(EXCEL)
BI – Design Studio
Lumira
PIC
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MII on HANA EM 2.0 BI – Operational View
01.12.2015 Seite 34
HANA DB
Control
Center
MES System(if in place)
WINCC
MII(Version independent)(if in place)
"traditional" Databases
MII 15.xOn HANA
Historian
Dashboards
PCOOPC Scada
PLC
15'
Buckets
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Central MII 15.x on HANA – Integration View
01.12.2015 Page 35
PIC
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Strong SAP ERP integration
01.12.2015 Seite 36
Master Data stored in ERP
Master Data
Production
Cost Center
Products
Meter Config
SAP ERP
MII – System
Full
Global
Modules
PM
PP
….
PIC =
Plant information
Catalog
Basic settings
Company data
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Plant Integration
01.12.2015 Seite 37
PI
MII – System
Full
Global
Modules
MII – System
LOCAL
Function
Modules
MII – System
LOCAL
Function
Modules
MII – System
LOCAL
Function
Modules
MII – System
LOCAL
Function
Modules
PI
Ferrero Plant MII Systems
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POC Progress
• System Design Process– Concept with SAP
– BBP finalized
– HANA design finalized
• Ongoing Tasks – Co-Innovation Tasks with SAP ongoing
– Continous approval with stakeholders
– Continous POC systems improvements
– Build additional HANA DB, Views
– Loading Test Data (~ 30th June, 2015)
• POC Evaluation
01.12.2015 Page 38
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Project Schedule
01.12.2015 Page 39
Sept - DezMay - AugJan - Apr
2014
Sept - DezMay - AugJan - Apr
2015
POC
MII Upgrade
HANA Setup
Evaluation
Concept Phase
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HANA Tools - Power Designer
01.12.2015 Page 40
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SAP Hana Studio
01.12.2015 Seite 41
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Reporting Example with LUMIRA
01.12.2015 Seite 42
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Reporting Example with LUMIRA
01.12.2015 Seite 43
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Reporting Example with LUMIRA
01.12.2015 Seite 44
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Benefits
Very simple:
All improvements and constant opimization
is finally saving our Job's because we are
competitive despite high labor costs in Germany
01.12.2015 Seite 45
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Thank you!
01.12.2015 Page 46