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Logistics Control CenterReiner Bildmayer, SAP AG, 27.09.2007

Workshop WS-23Die allwissende Fabrik - Informatik in der Produktion

Title

Demo of a Prototype

Motivation for a Logistics Control Center

Monitor and Control the Interaction of ERP& Manufacturing Operations

SAP AG 2007, Logistics Control Center / Reiner Bildmayer / 3

Competitive pressures and commoditization is forcing theneed to lower manufacturing costs.

Manufacturing nodes are being pushed out to distantlocations leading to a loss of visibility and control.

Velocity is critical. Time-to-market, Time to Volume, andTime to Scale are the keys to success.

Stringent regulations are driving the need for quality andgenealogy tracking and compliance capabilities

Connecting the Factory to the Enterprise and Supply Chain iscritical to cost-effectively deliver on customer expectations

Manufacturing today has some key challenges


ERP

* Shop Floor Automation and Control Systems

MES

SFAC*

How are we hitting our targets?Total Cost of Production and VarianceLabor and Resource ProductivityOrder Fill Rates and Cycle TimesFixed and Variable Asset Utilization

?

What’s happening during every shift?Material availability and consumptionCapacity availability and utilizationSchedule changesProduct Genealogy tracking and QM

?

What’s happening at each line?Cycle Times / Operating EfficienciesMachine Breakdowns / Unplanned DowntimeQuality IndexPredictive Maintenance requirements

?

The disconnect between the Factory and the Enterprise needs tobe addressed to meet these challenges

DISCONNECT

DISCONNECT

DISCONNECTDISCONNECT


Analyst View on the Future of Manufacturing

“Changing business models, coupled with an explosion of demand-side and supply-side production information requirements, haveforced manufacturers to rethink their plant systems deployments. Inresponse, manufacturers will seek to extend their applications modelbeyond the execution focus within the "four walls" of the plant,enabling greater visibility and collaboration in product value chainsacross the enterprise and its trading community.” - Ken Brant

“This new breed of collaborative manufacturing solutions enables anenterprise to derive maximum performance from their production andhuman assets by making critical information easily and broadlyavailable, and by dynamically aligning employees priorities with real-time objectives.” - Greg Gorbach

“The X Internet boosts flexibility and will let manufacturers improveplanning and visibility by connecting shop-floor assets like WIPinventory and equipment to enterprise apps. Smart firms will avoiddata overload by learning to manage their shop-floor operations byexception.” - Jennifer Chew

“Collaborative Manufacturing Execution requires a shift from bottomup Manufacturing IT and engineering silos, to top-down overarchingbusiness and production process management platforms extendedover multiple lines and production sites.” - Roddy Martin

Demo of a Prototype




ERP Today…A means of supporting people, processes and innovation

SeniorManagers

Supply ChainAnalysts

ProductionAnalysts

FinancialAnalysts

AccountExecutives

Employees


Manufacturing Operations Today …A combination of MES, SCADA, SPC, Historians etc.

Factory/Plant

Machinery & Plant Assets

Heterogeneous Plant Floor IT Infrastructure

Manufacturers need to:

Interact with various Systems andSolutions

Proactively detect machine, labor,quality, and resource exceptions

Collaborate with their suppliers andmanufacturing partners to resolveexceptions

Continuously monitor, analyze, andlearn from variances to improveprocesses

Provide production personnel withthe decision support and content theyneed to meet their targets


The New Reality Requires a Manufacturing OperationsManagement (MOM) Approach

ERP

MES

SFAC

DISCONNECT

SFAC

Global Coordination

DISCONNECT

ERP

Manufacturing

Operations

Management

Plant/Local Execution


MES

SFAC*

ERP and Manufacturing Operations Management need to have aseamless Monitoring and Control …

Logistic Control Center

Monitoring:Production OrdersMaterial FlowResources Business ViewResources Technical View,but no replacement for SCADAMaintenance of Resources…

Controlling:Production PlanningProduction Process…

SFAC

Global Coordination

ERP

Manufacturing

Operations

Management

Plant/Local Execution


… because there are gaps to be bridged due to differentgranularities …

EnterpriseFactory

User Interfaces

Resources

ResourcesStatus

ProduceActivities

otherEntities

Production Order,planned Quantities, ... Production Lot, Bin Quantities, ...


… additionally aggregation rules have to be established …

Aggregated factory/warehouse

The user can interfere to correct production flow in response to real time machine conditions

Production Overview

Final Assembly Detailed Overview


Business Objects

… and also the UI behavior and interactions must be mapped

Visualization Objects

Interactions

SizeColorLineFormTexture

AttributesMapping Business Object 1

Attribute 1Attribute 2

Business Object 2Attribute 1Attribute 2

Business Object 3Attribute 1Attribute 2Attribute 3Interaction

Mapping

2D/3D/Geo Scene – UI View System Entities

Demo of a Prototype




Demo Prototype

Logistics Control CenterReiner Bildmayer, SAP AG, 27.09.2007

Workshop WS-23Die allwissende Fabrik - Informatik in der Produktion

Title


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