Description
Marketing plan for a product based on the characteristics of the target market, market share objectives, desired product positioning within the market, and profit objectives.
Advanced Manufacturing Summit SAP Manufacturing Execution
Product Strategy and Roadmap
September 17, 2009
Tracy Wiese Sr. Solution Advisor
SEE YOUR WAY CLEAR
Strategies for Success in the New Reality
Disclaimer
The information in this presentation is confidential and proprietary to SAP and may not be disclosed without the permission of SAP. This presentation is not subject to your license agreement or any other service or subscription agreement with SAP. SAP has no obligation to pursue any course of business outlined in this document or any related presentation, or to develop or release any functionality mentioned therein. This document, or any related presentation about SAP’s strategy and possible future developments, directions, and functionality of products and/or platforms, are all subject to change and may be changed by SAP at any time for any reason without notice. The information in this document is not a commitment, promise, or legal obligation to deliver any material, code, or functionality. This document is provided without a warranty of any kind, either express or implied, including but not limited to, the implied warranties of merchantability, fitness for a particular purpose, or noninfringement. This document is for informational purposes and may not be incorporated into a contract. SAP assumes no responsibility for errors or omissions in this document, except if such damages were caused by SAP intentionally or grossly negligent. All forward-looking statements are subject to various risks and uncertainties that could cause actual results to differ materially from expectations. Readers are cautioned not to place undue reliance on these forward-looking statements, which speak only as of their dates, and they should not be relied upon in making purchasing decisions.
Agenda
1. SAP ME Roadmap
1. 2. 3. 4. 1. 2. SAP ME Core Application Integration to ECC via MII Integration to Machines via PCO Integration to Business Objects Core Community
2. SAP ME Strategy
SAP Manufacturing Execution Strategy
- Leverage current capabilities’, while building a bridge to the future
Manufacturing Integration and Intelligence (SAP MII) - provides a direct
connection between shop-floor systems and business operations. It ensures that all data that affects manufacturing is visible in real time - including information about orders, materials, equipment status, costs, and product quality.
Manufacturing Execution (SAP ME) - is functionally rich to provide real-time data
capture and global visibility across a manufacturing line, plant, or enterprise, to accurately track and manage work-in-progress (WIP) to ensure the right products are being made at the right time; optimize plant performance and profitability; improve quality and reduce variation and prevent escape of defective products.
Reduce Cycle Time with Integration, Intelligence and Collaboration Collaboration … Improve Visibility and Situational Awareness with a World Class… Class… Manufacturing Execution Strategy
SAP Manufacturing Execution (SAP ME)
SAP Manufacturing Execution
• • • Manages and controls manufacturing and shop floor operations Integrates business systems to the shop floor Complete component and item-level visibility for single and global operations
Traceability Non-conformance Management Test and Repair Engineering Change Management Labor Tracking Production Transfer Return and Repair Production Metrics Machine Integration Layer ECC Integration
The Markets We Serve
Complex, Discrete Manufacturing
Aerospace & Defense
High Tech
Automotive & Auto Electronics
Medical Device
Industrial Machinery & Components
high volume/low mix maketo-stock repetitive manufacturing
low volume/high mix buildto-order assembly manufacturing
Complex Assembly User Interface (Rich POD)
Simple User Interface (Standard POD)
The plant in your pocket
Mobile device example
Keyboard-less & Machine Integration
© SAP 2008 / Page 10
Process Enforcement
Flexible process flow allows for easy Drag-and-Drop linkage of operations into workflow steps. Business rules allow for alternate operations, embedded routes, standard process definition of rework and material review board (MRB). Route flow also supports dynamic routing based upon test results or business rules.
Poka-Yoke – Error Proofing – Quality Gating
Prevent Escapes – Check for open Nonconformances
Prevent work against jobs on hold – Value Add verification
Verify correct operator with up-to-date certification
Correct Material consumed at specific times
Material, Machine, Man, Method No defects, No breakdowns, Correct operator, Defined Process
Device History Report
SAP ME Standard Dashboards and Reporting
SAP Manufacturing Execution (SAP ME)
SAP Manufacturing Execution
• • • Manages and controls manufacturing and shop floor operations Integrates business systems to the shop floor Complete component and item-level visibility for single and global operations
Traceability Non-conformance Management Test and Repair Engineering Change Management Labor Tracking Production Transfer Return and Repair Production Metrics Machine Integration Layer ECC Integration
SAP Technology Standards
Application Structure User Interface Security Archiving Internationalization Integration framework Customization Approach Performance Diagnostics and Supportability Documentation
SAP ME – Future Functional Scope Items
Scope Item Rich POD Release 6.0 Description Enhance web-based POD UI to incorporate Rich UI technologies that create a more desirable user experience for shop floor operators. Existing Java Swing POD technology will be replaced. A new POD layout that provides complete visibility to the user for an order/lot/serialized part that is needed during the manufacturing process.
Shop Display
6.0
In-line Sampling
6.0
Refers to the ability to define Sample Plans and execute against those plans during the manufacturing process. Refers to sampling on Work In Process (WIP) and not on raw material or components. Explore an interface w/SAP QM for to retrieve sampling plan. The ability to award users with partial credit for setup and run time at an operation or for an order. Ability for multiple operators to work on an order at the same operation and claim individual earned standards. Ability to track partial completion of an operation where long processing times occur. Refactoring current NC functionality to enhance its extensibility for future internal, partner, or customer development. The Message Board is a electronic bulletin board type communication tool used on the shop floor that allows shop floor workers to manually request support and for support personnel to respond to those support requests. (Interface to SAP-Mail to process messages back to SAP.) Maintaining floor stock w/locations at the operation level that have minimum thresholds that if reached would trigger a replenishment signal to the ERP. Send a completion signal to trigger the movement of manufactured material to an inventory location on the shop floor for immediate consumption. Create a pick list location that can centralize floor stock for subsequent consumption feeds to operation/work center locations. If floor stock reaches zero or below, allow the capability for the system to continue to assemble.
Earned Standards
6.0
Nonconformance Extensibility
6.0
Message Board
6.0
Floor Stock Management
6.0
Continued
SAP ME 6.0 – Functional Scope Items
Scope Item Device History Record Enhancement Release 6.0 Description A report displays all historical data for a manufactured production unit in single view. It provides information on all activities performed, as well as on the data collected for a manufactured production unit. Refers to ability to predefine a list of values for the user for user defined data fields that are collected either in “define” mode or during manufacturing.
Data Value List
6.0
Visual Test & Repair
6.0
Replacing the D2B Viewer in the PCA Dashboard w/Right Hemisphere Deep View (coordination w/PLM group). Enhance current functionality by creating a more generic solution to support the identification, nonconformance, and repair of components through graphics, pictures, and multiple CAD types. Enhancing current labor functionality (e.g. Supervisor Time Edit) by allowing an operator/supervisor to view, enter, edit, and approve labor time against orders/operations on a daily/shift basis. Need to support both an integrated (w/current labor tracking system performing the time collection) and potential independent mode (completed post shift w/manual entry of time). Smaller enhancements such as XML messages, 2D Barcode, System Config Copy,….etc. TBD
Electronic Time Card (Labor)
6.0
Miscellaneous Business Objects Integration
6.0 6.0
ERP Integration (MII)
6.0
Enhance SAPMEINT by adding several new inbound/outbound ERP interfaces, MII reports, and core changes as required. Integration enhancements being driven from the Floor Stock, Electronic Time Card, and Sampling scope items.
Agenda
1.
SAP ME Roadmap
1. 2. 3. 4. SAP ME Core Application Integration to ECC via MII Integration to Machines via PCO Integration to Business Objects Core Community
2.
SAP ME Strategy
1. 2.
System Synchronization – thru current v5.2
The integration between SAP and ME provides a seem-less pre-integrated Manufacturing Execution Solution. SAP ERP is the system of record for all Master Data, SAP ME is the system of record for all WIP data.
From SAP ERP to SAP ME Materials Material Classifications Routing BOMs Batch Record Inspection Characteristics Orders (Planned and Production) Inventory Issues w/Reservation Inventory Issues no Reservation Equipment Scheduled Downtime SAP MII
Field Mapping Data Transformations Guaranteed Delivery Visualization
From SAP ME to SAP ERP Operational Confirmation Order Confirmation (includes backflush) Order Scrap Equipment Un-Scheduled Downtime Equipment Usage Counts Inventory Return Inventory Scrap Inventory Remove Reservation Batch Confirmation Batch Characteristics Quality Notifications
20
SAP Application Modules Diagram
ME
ME
Customer Relationship Mgmt
CRM
SD MM
Sales & Distribution
FI
Financial Accounting
Supplier Relationship Mgmt
SRM
PP
Materials Mgmt.
CO
Controlling
AM
Fixed Assets Mgmt.
Production Planning
KM / BW
QM
Quality Mgmt.
Analytics xApps IS
Industry Solutions
Long Term Planning
PS
Project System
SM/PM
Service & Plant Maint HR Human Resources
ME
PLM
ME ME Product Lifecycle Mgmt
SAP® ME and ERP Integration
Available in Future 6.0 Release
SAP
Enterprise Resource Planning
Plant Maintenance Inventory and Warehouse Management
• Production Order • Planned Order • Material • BOM • Routing • Operation • RMA Service Orders • Material Classifications • Inventory Receipt w/ Batch • Inventory Reservation • Equipment Scheduled Downtime • UOM Support • Users with Certifications • Work Center/Resource • Serial Number • Operator Certification • Shop Floor Instructions • Inspection Lots • Work Order Management • Inventory Links and KANBAN Support • Sample Plan Definition • Project System Orders
TcM PLM Adapter
Quality Management Master Data Authoring and Engineering Change Management Production Planning
SAP
Manufacturing Execution
WIP (Lot and Serial #) Tracking and Genealogy Manufacturing Process Control Defect Tracking and Resolution Data Collection Labor Tracking
• Production Yield Confirmation • Production Scrap Confirmations • Planned Order Backflush • Planned Order Scrap • Component Consumption • Parent Batch Number • RMA Service Order Confirmation • Quality Notifications • Equipment Unscheduled Downtime • Equipment Usage • Inventory Return • Inventory Scrap • Inventory Unreserve • DC Batch and Batch Characteristics • UOM Support • Order Labor Time • Serial Number • Inspection Lots Results • Work Order Management • Inventory Links and KANBAN
Support • Sample Results • Goods Movement of Planned Order Components • Rework Time Capture • Order Status WIP Update
SAP ME ERP Integration (MII)
Version 1.0 (MII 11.5, ME 4.3, NW 7.0) Date Released • • • • • • Outbound (SAP ERP > ME) Production Order Create/Update Material – Create/Update BOM – Create/Update Operation – Create/Update Routing – Create/Update Inbound (ME > SAP ERP) • Production Yield • Production Scrap MII Reports • WIP Reports • Data Type Enrichment
2.0 (MII 12.0, ME 5.1, NW 7.0)
ATS Q3/2008
• Planned Order Create/Update
• • • •
Planned Order Backflush Planned Order Scrap Component Consumption Parent Batch Number
Batch Traceability GUI
5.2 (MII 12.1, ME 5.2, NW 7.1)
RTC 19 June, 2009 followed by SP1 & SP2
• • • • •
Service Orders Material Classifications Inventory Receipt w/ Batch Inventory Reservation Equipment Status Change – Planned • UOM Support • User with certification • Work center/resource • • • • • • • • Serial Number Shop Floor Instructions Inspection Lots Work Order Management Inventory Links and KANBAN Phantom BOM Support Sample Plan Definition Project System Orders
• • • • • • • •
RMA Service Order Confirmation Quality Notifications Order Labor Time Equipment Unplanned Downtime Equipment Usage Maintain Inventory DC Batch and Batch Characteristics UOM Support
Where’s My Order OEE Production Line Monitor
6.0 (MII 12.2, ME 6.0, NW 7.1)
RTC Planned Q4/2010
Serial Numbers Inspection Lots Results Work Order Management Inventory Links and KANBAN Goods Movement of Planned Order Components • Support Multiple Batches per Order • Sample results • Rework Time Capture
• • • • •
TBD
Agenda
1.
SAP ME Roadmap
1. 2. 3. 4. SAP ME Core Application Integration to ECC via MII Integration to Machines via PCO Integration to Business Objects Core Community
2.
SAP ME Strategy
1. 2.
SAP ME Connectivity Layer Enhancements SAP Plant Connectivity 2.0
Enable introduction of execution capabilities through “smarter” connectors
Improved interoperability shop floor ERP system Increased responsiveness to drive performance Improved connectivity/interoperability with MES partners
Event-based and “listener” model Connectors
The ability to monitor unsolicited events and take some action based on event detection Events can be data changes, rule violations, etc. – any message with a business context (as opposed to a process control context) Built-in rules engine for event detection / notification Enable events to trigger business logic / transactional updates Message/command-based interaction with production systems Better exception management
Specifically, new event agents for:
OPC-DA OPC-UA OPC-A&E Socket Agent (for enabling of QM scenarios)
© SAP 2008 / Page 25
Small (< 20 MB), lightweight installation that is up and running in minutes! (.NET required)
SAP ME Equipment Integration
Strategy
Our strategy is to provide a suite of tools that assist SAP consultants, system integration partners, and customers to integrate shop floor equipment with SAP ME to rapidly reduce cost through reusability and speed of deployment. The Equipment Integration functionality supporting SAP ME will rely on a new integration tool (SAP ME Equipment Integration Layer (EIL)) developed and integrated with the new Plant Connectivity (PCo) tool. The primary design goals are centered around ease of Implementation and providing deeper functionality to support a broader range of equipment and systems integrations. Based on Web Services, the new tool set will align Equipment Integration with the technologies and strategies employed by the SAP ME integration team.
Features
Extend the existing PCo functionality with new SAP ME Destination Extend the PCo Agents (SAP ME MIL) to address the data source requirements of SAP ME Workflow-driven design model Technology based on latest .NET standards Web Services support Standards-based technologies Provides out-of-the-box standard workflows for file parsers, database interfaces, OPC (PLC) and other common integrations
Benefits
Equipment Integration is a critical component to realizing the full value of the MES Well positioned to support environments w/heterogeneous shop floor equipment Ease of use enables rapid implementation of equipment interfaces for quicker implementation and reduced cost Technology standardization opens up the field of available system integration partners Leverages the progress and solutions of the PCo team including the .NET technology already in place Minimizes potential MES and PLM encroachment by Automation vendors such as Siemens w/in SAP accounts
SAP ME Equipment Integration Landscape
SAP ME
PCo ME Content Historian
Process Flow
Historian
UDS
Dashboard
Scada
t en v E
SAP ME
SAP Plant Connectivity
Further processing in ERP
MES
Standards: OPC DA / AE / UA / Socket
Event trapped and validated against trigger criteria. Custom Notification created and dispatched to Destination.
ME processes the event message received from Plant connectivity.
LIMS
All SAP ME capabilities like Alerts etc. dashboard, alerting or further process trigger can be enabled
© SAP 2008 / Page 28
PCo Event Notifications in a nutshell
SAP Plant Connectivity Agent
Notification Message
Destination
ME
Agents communicate with Plant systems and subscribe to available Plant system events Agents generate Notification Messages based on incoming Plant system events and user-defined business context Destinations deliver Notification Messages to respective systems
© SAP 2008 / Page 29
29
Solution Overview
ME
Plant Floor Application Layer
Connectivity
Plant Connectivity
Plant Floor Equipment Layer
SAP ME Destination File Listener Agent OPC Agent Additional Agents
Real-time event notification + (PCo 2.1) High-performance query and command execution
Note: Bubble size bands estimate of relative sizes of solution priorities.
SAP ME – Plant Connectivity (PCo) Roadmap
Version Date RTC Planned Q3/2009 Planned Functional Enhancements • • • • • • • • • • • • • • • • SAP ME Workflow Destination Scripting Engine (C#) Workflow Activity OPC Automated Data Collection based on PCo core functionality File Monitor Agent Timer Agent Port PCo 2.0 Extensions to PCo 2.1 Cogiscan PFC Agent MYDATA Integration Agent Siemens SMT Integration Agent File Monitor Agent Enhancements Port PCo 2.1 Extensions to PCo 2.2 Bi-directional Socket Agent SAP ME Workflow Destination Enhancements SAP ME Hook Point Extension SECS/GEM Agent Serial Stream Agent
GEM ME OPC PCo PFC RTC SECS SEMI SMT Generic Equipment Model Manufacturing Execution OLE for Process Control Plant Connectivity Product Flow Controller Release to Customers SEMI Equipment Communications Standard Semiconductor Surface Mount Technology
ME 5.2
PCo 2.0 Extensions
ME 5.2
PCo 2.1 Extensions
RTC Planned Q1/2010
ME 6.0
PCo 2.2 Extensions
RTC Planned Q4/2010
SAP ME-PCo Roadmap Details
A&E DA ICT UA
Alerts and Events Data Access In Circuit Test Unified Architecture
Relea se
ME 5.2
Compon ent
PCo 2.0
Enhancement
SAP ME Workflow Destination
Description
Provide a PCo destination for SAP ME 5.2. This will enable SAP ME to obtain data and information from PCo agents connected to shop floor equipment. It will include a flexible workflow process for generation of ME interface messages and for error handling. Provide a scripting capability as a workflow activity for the SAP ME Workflow destination. This will provide additional flexibility in the logic and computational capabilities for the processing of information from PCo agents. Provide automated data collection for SAP ME using PCo OPC agents. This will include support for OPC DA, OPC UA and OPC A&E. However, with PCo 2.0, only one way (receive) communication from the OPC device is supported. Provide a PCo agent that enables the configuration of file scanners for parsing the information in a file and extracting the needed data. This will support traditional integrations such as ICT file parsing. Features will include: File Mask Folder to Monitor Frequency to Monitor Handling of file once processed (Delete, Move, Rename, Nothing) Authentication to remote shares on the domain Provide a PCo timer agent to enable collecting information on a periodic basis. This will enable transactions such as polling an external source and monitoring a database table for specific rows.
ME 5.2
PCo 2.0
Scripting Engine (C#) Workflow Activity OPC Automated Data Collection based on PCo core functionality File Monitor Agent
ME 5.2
PCo 2.0
ME 5.2
PCo 2.0
ME 5.2
PCo 2.0
Timer Agent
SAP ME-PCo Roadmap Details
Relea se
ME 5.2 ME 5.2
Compone nt
PCo 2.1 PCo 2.1
Enhancement
Port PCo 2.0 Extensions to 2.1 Cogiscan PFC Agent
Description
Provide all of the SAP ME PCo 2.0 extensions in the PCo 2.1 environment. Provide a PCO 2.1 agent to support the interface requirements of the Cogiscan Product Flow Controller. This will enable SAP ME to monitor and control product flow in the factory. This agent will replace the VMIL functionality currently in use at Harman Becker. Provide a PCO 2.1 agent to support the MYDATA pick and place machines integration as implemented in VMIL. Provide a PCO 2.1 agent to support bi-directional communication with Siemens SMT equipment. This will enable SAP ME to monitor and control many different models of Siemens SMT equipment. Enhance the SAP ME PCo file monitor agent to enable monitoring a single file whose content is changing over time.
ME 5.2 ME 5.2
PCo 2.1 PCo 2.1
MYDATA Integration Agent Siemens SMT Integration Agent File Monitor Agent Enhancements
ME 5.2
PCo 2.1
VMIL
Visiprise Manufacturing Integration Layer
SAP ME-PCo Roadmap Details
Relea se
ME 6.0
Compone nt
PCo 2.2
Enhancement
Port PCo 2.1 Extensions to PCo 2.2 Bi-Directional Socket Agent
Description
Provide all of the SAP ME PCo 2.1 extensions in the PCo 2.2 environment.
ME 6.0
PCo 2.2
Provide an SAP ME PCo agent that enables bi-directional communication via one (or more) socket connections to a source system. This will enable the SAP ME PCo agent to connect to a socket and send commands to the source system, as well as to receive data and commands from the source system. Provide the capability to configure all resources & workflows within the SAP ME PCo destination. This will include the capability to serialize the landscape configuration to the PCo configuration data store within the SAP ME destination itself (for internal processing). Provide the capability to associate agent Instances to specific SAP ME resource + workflow definitions. That is, there will be one SAP ME PCo landscape definition; but it will be possible to associate PCO 2.2 agents to specific resource + workflow configuration definitions. Each landscape can have 1..n resource & resource group definitions.
ME 6.0
PCo 2.2
SAP ME Workflow Destination Enhancements
ME 6.0
PCo 2.2
SAP ME Hook Point Extension SECS/GEM Agent
Provide a mechanism for ME hook point activities to trigger factory floor events via a PCo 2.2 agent (e.g. Place a physical piece of equipment in a HOLD state). Provide an SAP ME PCo 2.2 agent that supports the SECS/GEM standard for communicating with semiconductor manufacturing equipment. The specific standard will likely be SECS II which utilizes TCP/IP. Provide an SAP ME PCo 2.2 agent that provides the capability to receive data from a device via a serial port. This will include the capability to parse the incoming data stream to obtain the relevant information.
ME 6.0
PCo 2.2
ME 6.0
PCo 2.2
Serial Stream Agent
TCP/IP
Transport Control Protocol / Internet Protocol
SAP Manufacturing Execution - PCo Agents
ME 5.2 PCo 2.0 Agents
• File Monitor • OPC Automated Data Collection • Timer
ME 5.2 PCo 2.1 Agents
• • • • All above agents Cogiscan PFC My Data Integration Siemens SMT
ME 6.0 PCo 2.2 Agents
• • • • All above agents Bi-directional Socket SECS/GEMS Serial Stream
Agenda
1.
SAP ME Roadmap
1. 2. 3. 4. SAP ME Core Application Integration to ECC via MII Integration to Machines via PCO Integration to Business Objects Core Community
2.
SAP ME Strategy
1. 2.
Production Monitoring: Business Objects Standard Reports
14 universes Developed in English with Chinese, German, French, and Japanese translations Most data from ME ODS, but some from ME WIP (synonyms used to combine data sources) 25 predefined reports Using no translation relevant information beyond that in the universes All data from ME 20 LOVs (list of values) For selecting ME objects such as Site, Item, SFC Satisfies ME object browse requirement Time Granularity support At universe and report level Both system (hour, day, month) and custom (shift, quarter, year) granularities
37
SAP ME Reporting Infrastructure
JSP Audit Log Reports
BOBJ 14 Universes 25 Reports
BOBJ 14 Universes 25 Reports
JSP Reports 50+
MII Visualization
Production Monitoring: Business Objects Web Intelligence
Business Objects Web Intelligence allows users to
Run, copy and edit predefined web intelligence reports, scheduled and on demand Perform ad-hoc quiries and create new reports Modify and extend universes with Business Objects Universe Designer software Translate universes with Business Objects Translation Manager
39
Production Monitoring: Viewing ME ODS Reports using WEBI
40
Production Monitoring: Access to Predefined Reports/ Prompt for Filter
41
Production Monitoring: INFOVIEW Access to Predefined Reports
42
Business Objects - Polestar
43
Business Objects - xCelsius
44
Agenda
SAP ME Roadmap
SAP ME Core Application Integration to ECC via MII Integration to Machines via PCO Integration to Business Objects
SAP ME Strategy
Core Community
SAP Application Modules Diagram
ME
ME
Customer Relationship Mgmt
CRM
SD MM
Sales & Distribution
FI
Financial Accounting
Supplier Relationship Mgmt
SRM
PP
Materials Mgmt.
CO
Controlling
AM
Fixed Assets Mgmt.
Production Planning
KM / BW
QM
Quality Mgmt.
Analytics xApps IS
Industry Solutions
Long Term Planning
PS
Project System
SM/PM
Service & Plant Maint HR Human Resources
ME
PLM
ME ME Product Lifecycle Mgmt
In Pursuit of the Perfect Plant
Deploy Quickly, Drive Rapid Return on Investment The “Perfect Plant” is the ultimate goal - to optimize effectiveness of your manufacturing assets and drive increased performance in concert with the Enterprise Plan & Objectives.
The Perfect Plant:
• • • • • •
Leverage the investment in your (existing) Enterprise Applications Radically simplify business processes delivered to the front-line operator Exploit and extend the existing manufacturing infrastructure Integrate shop floor information with the rest of the supply chain Provide actionable intelligence through role-based interaction Supports the Operational Excellence Programs & Teams in Real-time
SAP Manufacturing Execution Critical Execution / Enforcement Capability Pre-built SAP integration via MII Pre-built Business Objects integration Significant success within Discrete Mfg Industries
SAP MII The Flexible Connector Delivers Role-based Content and Context Combination of Data Access, Business Logic, Quality and Visualization Services, as well as Alerting, Metrics, KPIs
Upcoming Events
Working with Marketing to fill in
Thank you!
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© SAP 2007 / Page 50
doc_834746219.pdf
Marketing plan for a product based on the characteristics of the target market, market share objectives, desired product positioning within the market, and profit objectives.
Advanced Manufacturing Summit SAP Manufacturing Execution
Product Strategy and Roadmap
September 17, 2009
Tracy Wiese Sr. Solution Advisor
SEE YOUR WAY CLEAR
Strategies for Success in the New Reality
Disclaimer
The information in this presentation is confidential and proprietary to SAP and may not be disclosed without the permission of SAP. This presentation is not subject to your license agreement or any other service or subscription agreement with SAP. SAP has no obligation to pursue any course of business outlined in this document or any related presentation, or to develop or release any functionality mentioned therein. This document, or any related presentation about SAP’s strategy and possible future developments, directions, and functionality of products and/or platforms, are all subject to change and may be changed by SAP at any time for any reason without notice. The information in this document is not a commitment, promise, or legal obligation to deliver any material, code, or functionality. This document is provided without a warranty of any kind, either express or implied, including but not limited to, the implied warranties of merchantability, fitness for a particular purpose, or noninfringement. This document is for informational purposes and may not be incorporated into a contract. SAP assumes no responsibility for errors or omissions in this document, except if such damages were caused by SAP intentionally or grossly negligent. All forward-looking statements are subject to various risks and uncertainties that could cause actual results to differ materially from expectations. Readers are cautioned not to place undue reliance on these forward-looking statements, which speak only as of their dates, and they should not be relied upon in making purchasing decisions.
Agenda
1. SAP ME Roadmap
1. 2. 3. 4. 1. 2. SAP ME Core Application Integration to ECC via MII Integration to Machines via PCO Integration to Business Objects Core Community
2. SAP ME Strategy
SAP Manufacturing Execution Strategy
- Leverage current capabilities’, while building a bridge to the future
Manufacturing Integration and Intelligence (SAP MII) - provides a direct
connection between shop-floor systems and business operations. It ensures that all data that affects manufacturing is visible in real time - including information about orders, materials, equipment status, costs, and product quality.
Manufacturing Execution (SAP ME) - is functionally rich to provide real-time data
capture and global visibility across a manufacturing line, plant, or enterprise, to accurately track and manage work-in-progress (WIP) to ensure the right products are being made at the right time; optimize plant performance and profitability; improve quality and reduce variation and prevent escape of defective products.
Reduce Cycle Time with Integration, Intelligence and Collaboration Collaboration … Improve Visibility and Situational Awareness with a World Class… Class… Manufacturing Execution Strategy
SAP Manufacturing Execution (SAP ME)
SAP Manufacturing Execution
• • • Manages and controls manufacturing and shop floor operations Integrates business systems to the shop floor Complete component and item-level visibility for single and global operations
Traceability Non-conformance Management Test and Repair Engineering Change Management Labor Tracking Production Transfer Return and Repair Production Metrics Machine Integration Layer ECC Integration
The Markets We Serve
Complex, Discrete Manufacturing
Aerospace & Defense
High Tech
Automotive & Auto Electronics
Medical Device
Industrial Machinery & Components
high volume/low mix maketo-stock repetitive manufacturing
low volume/high mix buildto-order assembly manufacturing
Complex Assembly User Interface (Rich POD)
Simple User Interface (Standard POD)
The plant in your pocket
Mobile device example
Keyboard-less & Machine Integration
© SAP 2008 / Page 10
Process Enforcement
Flexible process flow allows for easy Drag-and-Drop linkage of operations into workflow steps. Business rules allow for alternate operations, embedded routes, standard process definition of rework and material review board (MRB). Route flow also supports dynamic routing based upon test results or business rules.
Poka-Yoke – Error Proofing – Quality Gating
Prevent Escapes – Check for open Nonconformances
Prevent work against jobs on hold – Value Add verification
Verify correct operator with up-to-date certification
Correct Material consumed at specific times
Material, Machine, Man, Method No defects, No breakdowns, Correct operator, Defined Process
Device History Report
SAP ME Standard Dashboards and Reporting
SAP Manufacturing Execution (SAP ME)
SAP Manufacturing Execution
• • • Manages and controls manufacturing and shop floor operations Integrates business systems to the shop floor Complete component and item-level visibility for single and global operations
Traceability Non-conformance Management Test and Repair Engineering Change Management Labor Tracking Production Transfer Return and Repair Production Metrics Machine Integration Layer ECC Integration
SAP Technology Standards
Application Structure User Interface Security Archiving Internationalization Integration framework Customization Approach Performance Diagnostics and Supportability Documentation
SAP ME – Future Functional Scope Items
Scope Item Rich POD Release 6.0 Description Enhance web-based POD UI to incorporate Rich UI technologies that create a more desirable user experience for shop floor operators. Existing Java Swing POD technology will be replaced. A new POD layout that provides complete visibility to the user for an order/lot/serialized part that is needed during the manufacturing process.
Shop Display
6.0
In-line Sampling
6.0
Refers to the ability to define Sample Plans and execute against those plans during the manufacturing process. Refers to sampling on Work In Process (WIP) and not on raw material or components. Explore an interface w/SAP QM for to retrieve sampling plan. The ability to award users with partial credit for setup and run time at an operation or for an order. Ability for multiple operators to work on an order at the same operation and claim individual earned standards. Ability to track partial completion of an operation where long processing times occur. Refactoring current NC functionality to enhance its extensibility for future internal, partner, or customer development. The Message Board is a electronic bulletin board type communication tool used on the shop floor that allows shop floor workers to manually request support and for support personnel to respond to those support requests. (Interface to SAP-Mail to process messages back to SAP.) Maintaining floor stock w/locations at the operation level that have minimum thresholds that if reached would trigger a replenishment signal to the ERP. Send a completion signal to trigger the movement of manufactured material to an inventory location on the shop floor for immediate consumption. Create a pick list location that can centralize floor stock for subsequent consumption feeds to operation/work center locations. If floor stock reaches zero or below, allow the capability for the system to continue to assemble.
Earned Standards
6.0
Nonconformance Extensibility
6.0
Message Board
6.0
Floor Stock Management
6.0
Continued
SAP ME 6.0 – Functional Scope Items
Scope Item Device History Record Enhancement Release 6.0 Description A report displays all historical data for a manufactured production unit in single view. It provides information on all activities performed, as well as on the data collected for a manufactured production unit. Refers to ability to predefine a list of values for the user for user defined data fields that are collected either in “define” mode or during manufacturing.
Data Value List
6.0
Visual Test & Repair
6.0
Replacing the D2B Viewer in the PCA Dashboard w/Right Hemisphere Deep View (coordination w/PLM group). Enhance current functionality by creating a more generic solution to support the identification, nonconformance, and repair of components through graphics, pictures, and multiple CAD types. Enhancing current labor functionality (e.g. Supervisor Time Edit) by allowing an operator/supervisor to view, enter, edit, and approve labor time against orders/operations on a daily/shift basis. Need to support both an integrated (w/current labor tracking system performing the time collection) and potential independent mode (completed post shift w/manual entry of time). Smaller enhancements such as XML messages, 2D Barcode, System Config Copy,….etc. TBD
Electronic Time Card (Labor)
6.0
Miscellaneous Business Objects Integration
6.0 6.0
ERP Integration (MII)
6.0
Enhance SAPMEINT by adding several new inbound/outbound ERP interfaces, MII reports, and core changes as required. Integration enhancements being driven from the Floor Stock, Electronic Time Card, and Sampling scope items.
Agenda
1.
SAP ME Roadmap
1. 2. 3. 4. SAP ME Core Application Integration to ECC via MII Integration to Machines via PCO Integration to Business Objects Core Community
2.
SAP ME Strategy
1. 2.
System Synchronization – thru current v5.2
The integration between SAP and ME provides a seem-less pre-integrated Manufacturing Execution Solution. SAP ERP is the system of record for all Master Data, SAP ME is the system of record for all WIP data.
From SAP ERP to SAP ME Materials Material Classifications Routing BOMs Batch Record Inspection Characteristics Orders (Planned and Production) Inventory Issues w/Reservation Inventory Issues no Reservation Equipment Scheduled Downtime SAP MII
Field Mapping Data Transformations Guaranteed Delivery Visualization
From SAP ME to SAP ERP Operational Confirmation Order Confirmation (includes backflush) Order Scrap Equipment Un-Scheduled Downtime Equipment Usage Counts Inventory Return Inventory Scrap Inventory Remove Reservation Batch Confirmation Batch Characteristics Quality Notifications
20
SAP Application Modules Diagram
ME
ME
Customer Relationship Mgmt
CRM
SD MM
Sales & Distribution
FI
Financial Accounting
Supplier Relationship Mgmt
SRM
PP
Materials Mgmt.
CO
Controlling
AM
Fixed Assets Mgmt.
Production Planning
KM / BW
QM
Quality Mgmt.
Analytics xApps IS
Industry Solutions
Long Term Planning
PS
Project System
SM/PM
Service & Plant Maint HR Human Resources
ME
PLM
ME ME Product Lifecycle Mgmt
SAP® ME and ERP Integration
Available in Future 6.0 Release
SAP
Enterprise Resource Planning
Plant Maintenance Inventory and Warehouse Management
• Production Order • Planned Order • Material • BOM • Routing • Operation • RMA Service Orders • Material Classifications • Inventory Receipt w/ Batch • Inventory Reservation • Equipment Scheduled Downtime • UOM Support • Users with Certifications • Work Center/Resource • Serial Number • Operator Certification • Shop Floor Instructions • Inspection Lots • Work Order Management • Inventory Links and KANBAN Support • Sample Plan Definition • Project System Orders
TcM PLM Adapter
Quality Management Master Data Authoring and Engineering Change Management Production Planning
SAP
Manufacturing Execution
WIP (Lot and Serial #) Tracking and Genealogy Manufacturing Process Control Defect Tracking and Resolution Data Collection Labor Tracking
• Production Yield Confirmation • Production Scrap Confirmations • Planned Order Backflush • Planned Order Scrap • Component Consumption • Parent Batch Number • RMA Service Order Confirmation • Quality Notifications • Equipment Unscheduled Downtime • Equipment Usage • Inventory Return • Inventory Scrap • Inventory Unreserve • DC Batch and Batch Characteristics • UOM Support • Order Labor Time • Serial Number • Inspection Lots Results • Work Order Management • Inventory Links and KANBAN
Support • Sample Results • Goods Movement of Planned Order Components • Rework Time Capture • Order Status WIP Update
SAP ME ERP Integration (MII)
Version 1.0 (MII 11.5, ME 4.3, NW 7.0) Date Released • • • • • • Outbound (SAP ERP > ME) Production Order Create/Update Material – Create/Update BOM – Create/Update Operation – Create/Update Routing – Create/Update Inbound (ME > SAP ERP) • Production Yield • Production Scrap MII Reports • WIP Reports • Data Type Enrichment
2.0 (MII 12.0, ME 5.1, NW 7.0)
ATS Q3/2008
• Planned Order Create/Update
• • • •
Planned Order Backflush Planned Order Scrap Component Consumption Parent Batch Number
Batch Traceability GUI
5.2 (MII 12.1, ME 5.2, NW 7.1)
RTC 19 June, 2009 followed by SP1 & SP2
• • • • •
Service Orders Material Classifications Inventory Receipt w/ Batch Inventory Reservation Equipment Status Change – Planned • UOM Support • User with certification • Work center/resource • • • • • • • • Serial Number Shop Floor Instructions Inspection Lots Work Order Management Inventory Links and KANBAN Phantom BOM Support Sample Plan Definition Project System Orders
• • • • • • • •
RMA Service Order Confirmation Quality Notifications Order Labor Time Equipment Unplanned Downtime Equipment Usage Maintain Inventory DC Batch and Batch Characteristics UOM Support
Where’s My Order OEE Production Line Monitor
6.0 (MII 12.2, ME 6.0, NW 7.1)
RTC Planned Q4/2010
Serial Numbers Inspection Lots Results Work Order Management Inventory Links and KANBAN Goods Movement of Planned Order Components • Support Multiple Batches per Order • Sample results • Rework Time Capture
• • • • •
TBD
Agenda
1.
SAP ME Roadmap
1. 2. 3. 4. SAP ME Core Application Integration to ECC via MII Integration to Machines via PCO Integration to Business Objects Core Community
2.
SAP ME Strategy
1. 2.
SAP ME Connectivity Layer Enhancements SAP Plant Connectivity 2.0
Enable introduction of execution capabilities through “smarter” connectors
Improved interoperability shop floor ERP system Increased responsiveness to drive performance Improved connectivity/interoperability with MES partners
Event-based and “listener” model Connectors
The ability to monitor unsolicited events and take some action based on event detection Events can be data changes, rule violations, etc. – any message with a business context (as opposed to a process control context) Built-in rules engine for event detection / notification Enable events to trigger business logic / transactional updates Message/command-based interaction with production systems Better exception management
Specifically, new event agents for:
OPC-DA OPC-UA OPC-A&E Socket Agent (for enabling of QM scenarios)
© SAP 2008 / Page 25
Small (< 20 MB), lightweight installation that is up and running in minutes! (.NET required)
SAP ME Equipment Integration
Strategy
Our strategy is to provide a suite of tools that assist SAP consultants, system integration partners, and customers to integrate shop floor equipment with SAP ME to rapidly reduce cost through reusability and speed of deployment. The Equipment Integration functionality supporting SAP ME will rely on a new integration tool (SAP ME Equipment Integration Layer (EIL)) developed and integrated with the new Plant Connectivity (PCo) tool. The primary design goals are centered around ease of Implementation and providing deeper functionality to support a broader range of equipment and systems integrations. Based on Web Services, the new tool set will align Equipment Integration with the technologies and strategies employed by the SAP ME integration team.
Features
Extend the existing PCo functionality with new SAP ME Destination Extend the PCo Agents (SAP ME MIL) to address the data source requirements of SAP ME Workflow-driven design model Technology based on latest .NET standards Web Services support Standards-based technologies Provides out-of-the-box standard workflows for file parsers, database interfaces, OPC (PLC) and other common integrations
Benefits
Equipment Integration is a critical component to realizing the full value of the MES Well positioned to support environments w/heterogeneous shop floor equipment Ease of use enables rapid implementation of equipment interfaces for quicker implementation and reduced cost Technology standardization opens up the field of available system integration partners Leverages the progress and solutions of the PCo team including the .NET technology already in place Minimizes potential MES and PLM encroachment by Automation vendors such as Siemens w/in SAP accounts
SAP ME Equipment Integration Landscape
SAP ME
PCo ME Content Historian
Process Flow
Historian
UDS
Dashboard
Scada
t en v E
SAP ME
SAP Plant Connectivity
Further processing in ERP
MES
Standards: OPC DA / AE / UA / Socket
Event trapped and validated against trigger criteria. Custom Notification created and dispatched to Destination.
ME processes the event message received from Plant connectivity.
LIMS
All SAP ME capabilities like Alerts etc. dashboard, alerting or further process trigger can be enabled
© SAP 2008 / Page 28
PCo Event Notifications in a nutshell
SAP Plant Connectivity Agent
Notification Message
Destination
ME
Agents communicate with Plant systems and subscribe to available Plant system events Agents generate Notification Messages based on incoming Plant system events and user-defined business context Destinations deliver Notification Messages to respective systems
© SAP 2008 / Page 29
29
Solution Overview
ME
Plant Floor Application Layer
Connectivity
Plant Connectivity
Plant Floor Equipment Layer
SAP ME Destination File Listener Agent OPC Agent Additional Agents
Real-time event notification + (PCo 2.1) High-performance query and command execution
Note: Bubble size bands estimate of relative sizes of solution priorities.
SAP ME – Plant Connectivity (PCo) Roadmap
Version Date RTC Planned Q3/2009 Planned Functional Enhancements • • • • • • • • • • • • • • • • SAP ME Workflow Destination Scripting Engine (C#) Workflow Activity OPC Automated Data Collection based on PCo core functionality File Monitor Agent Timer Agent Port PCo 2.0 Extensions to PCo 2.1 Cogiscan PFC Agent MYDATA Integration Agent Siemens SMT Integration Agent File Monitor Agent Enhancements Port PCo 2.1 Extensions to PCo 2.2 Bi-directional Socket Agent SAP ME Workflow Destination Enhancements SAP ME Hook Point Extension SECS/GEM Agent Serial Stream Agent
GEM ME OPC PCo PFC RTC SECS SEMI SMT Generic Equipment Model Manufacturing Execution OLE for Process Control Plant Connectivity Product Flow Controller Release to Customers SEMI Equipment Communications Standard Semiconductor Surface Mount Technology
ME 5.2
PCo 2.0 Extensions
ME 5.2
PCo 2.1 Extensions
RTC Planned Q1/2010
ME 6.0
PCo 2.2 Extensions
RTC Planned Q4/2010
SAP ME-PCo Roadmap Details
A&E DA ICT UA
Alerts and Events Data Access In Circuit Test Unified Architecture
Relea se
ME 5.2
Compon ent
PCo 2.0
Enhancement
SAP ME Workflow Destination
Description
Provide a PCo destination for SAP ME 5.2. This will enable SAP ME to obtain data and information from PCo agents connected to shop floor equipment. It will include a flexible workflow process for generation of ME interface messages and for error handling. Provide a scripting capability as a workflow activity for the SAP ME Workflow destination. This will provide additional flexibility in the logic and computational capabilities for the processing of information from PCo agents. Provide automated data collection for SAP ME using PCo OPC agents. This will include support for OPC DA, OPC UA and OPC A&E. However, with PCo 2.0, only one way (receive) communication from the OPC device is supported. Provide a PCo agent that enables the configuration of file scanners for parsing the information in a file and extracting the needed data. This will support traditional integrations such as ICT file parsing. Features will include: File Mask Folder to Monitor Frequency to Monitor Handling of file once processed (Delete, Move, Rename, Nothing) Authentication to remote shares on the domain Provide a PCo timer agent to enable collecting information on a periodic basis. This will enable transactions such as polling an external source and monitoring a database table for specific rows.
ME 5.2
PCo 2.0
Scripting Engine (C#) Workflow Activity OPC Automated Data Collection based on PCo core functionality File Monitor Agent
ME 5.2
PCo 2.0
ME 5.2
PCo 2.0
ME 5.2
PCo 2.0
Timer Agent
SAP ME-PCo Roadmap Details
Relea se
ME 5.2 ME 5.2
Compone nt
PCo 2.1 PCo 2.1
Enhancement
Port PCo 2.0 Extensions to 2.1 Cogiscan PFC Agent
Description
Provide all of the SAP ME PCo 2.0 extensions in the PCo 2.1 environment. Provide a PCO 2.1 agent to support the interface requirements of the Cogiscan Product Flow Controller. This will enable SAP ME to monitor and control product flow in the factory. This agent will replace the VMIL functionality currently in use at Harman Becker. Provide a PCO 2.1 agent to support the MYDATA pick and place machines integration as implemented in VMIL. Provide a PCO 2.1 agent to support bi-directional communication with Siemens SMT equipment. This will enable SAP ME to monitor and control many different models of Siemens SMT equipment. Enhance the SAP ME PCo file monitor agent to enable monitoring a single file whose content is changing over time.
ME 5.2 ME 5.2
PCo 2.1 PCo 2.1
MYDATA Integration Agent Siemens SMT Integration Agent File Monitor Agent Enhancements
ME 5.2
PCo 2.1
VMIL
Visiprise Manufacturing Integration Layer
SAP ME-PCo Roadmap Details
Relea se
ME 6.0
Compone nt
PCo 2.2
Enhancement
Port PCo 2.1 Extensions to PCo 2.2 Bi-Directional Socket Agent
Description
Provide all of the SAP ME PCo 2.1 extensions in the PCo 2.2 environment.
ME 6.0
PCo 2.2
Provide an SAP ME PCo agent that enables bi-directional communication via one (or more) socket connections to a source system. This will enable the SAP ME PCo agent to connect to a socket and send commands to the source system, as well as to receive data and commands from the source system. Provide the capability to configure all resources & workflows within the SAP ME PCo destination. This will include the capability to serialize the landscape configuration to the PCo configuration data store within the SAP ME destination itself (for internal processing). Provide the capability to associate agent Instances to specific SAP ME resource + workflow definitions. That is, there will be one SAP ME PCo landscape definition; but it will be possible to associate PCO 2.2 agents to specific resource + workflow configuration definitions. Each landscape can have 1..n resource & resource group definitions.
ME 6.0
PCo 2.2
SAP ME Workflow Destination Enhancements
ME 6.0
PCo 2.2
SAP ME Hook Point Extension SECS/GEM Agent
Provide a mechanism for ME hook point activities to trigger factory floor events via a PCo 2.2 agent (e.g. Place a physical piece of equipment in a HOLD state). Provide an SAP ME PCo 2.2 agent that supports the SECS/GEM standard for communicating with semiconductor manufacturing equipment. The specific standard will likely be SECS II which utilizes TCP/IP. Provide an SAP ME PCo 2.2 agent that provides the capability to receive data from a device via a serial port. This will include the capability to parse the incoming data stream to obtain the relevant information.
ME 6.0
PCo 2.2
ME 6.0
PCo 2.2
Serial Stream Agent
TCP/IP
Transport Control Protocol / Internet Protocol
SAP Manufacturing Execution - PCo Agents
ME 5.2 PCo 2.0 Agents
• File Monitor • OPC Automated Data Collection • Timer
ME 5.2 PCo 2.1 Agents
• • • • All above agents Cogiscan PFC My Data Integration Siemens SMT
ME 6.0 PCo 2.2 Agents
• • • • All above agents Bi-directional Socket SECS/GEMS Serial Stream
Agenda
1.
SAP ME Roadmap
1. 2. 3. 4. SAP ME Core Application Integration to ECC via MII Integration to Machines via PCO Integration to Business Objects Core Community
2.
SAP ME Strategy
1. 2.
Production Monitoring: Business Objects Standard Reports
14 universes Developed in English with Chinese, German, French, and Japanese translations Most data from ME ODS, but some from ME WIP (synonyms used to combine data sources) 25 predefined reports Using no translation relevant information beyond that in the universes All data from ME 20 LOVs (list of values) For selecting ME objects such as Site, Item, SFC Satisfies ME object browse requirement Time Granularity support At universe and report level Both system (hour, day, month) and custom (shift, quarter, year) granularities
37
SAP ME Reporting Infrastructure
JSP Audit Log Reports
BOBJ 14 Universes 25 Reports
BOBJ 14 Universes 25 Reports
JSP Reports 50+
MII Visualization
Production Monitoring: Business Objects Web Intelligence
Business Objects Web Intelligence allows users to
Run, copy and edit predefined web intelligence reports, scheduled and on demand Perform ad-hoc quiries and create new reports Modify and extend universes with Business Objects Universe Designer software Translate universes with Business Objects Translation Manager
39
Production Monitoring: Viewing ME ODS Reports using WEBI
40
Production Monitoring: Access to Predefined Reports/ Prompt for Filter
41
Production Monitoring: INFOVIEW Access to Predefined Reports
42
Business Objects - Polestar
43
Business Objects - xCelsius
44
Agenda
SAP ME Roadmap
SAP ME Core Application Integration to ECC via MII Integration to Machines via PCO Integration to Business Objects
SAP ME Strategy
Core Community
SAP Application Modules Diagram
ME
ME
Customer Relationship Mgmt
CRM
SD MM
Sales & Distribution
FI
Financial Accounting
Supplier Relationship Mgmt
SRM
PP
Materials Mgmt.
CO
Controlling
AM
Fixed Assets Mgmt.
Production Planning
KM / BW
QM
Quality Mgmt.
Analytics xApps IS
Industry Solutions
Long Term Planning
PS
Project System
SM/PM
Service & Plant Maint HR Human Resources
ME
PLM
ME ME Product Lifecycle Mgmt
In Pursuit of the Perfect Plant
Deploy Quickly, Drive Rapid Return on Investment The “Perfect Plant” is the ultimate goal - to optimize effectiveness of your manufacturing assets and drive increased performance in concert with the Enterprise Plan & Objectives.
The Perfect Plant:
• • • • • •
Leverage the investment in your (existing) Enterprise Applications Radically simplify business processes delivered to the front-line operator Exploit and extend the existing manufacturing infrastructure Integrate shop floor information with the rest of the supply chain Provide actionable intelligence through role-based interaction Supports the Operational Excellence Programs & Teams in Real-time
SAP Manufacturing Execution Critical Execution / Enforcement Capability Pre-built SAP integration via MII Pre-built Business Objects integration Significant success within Discrete Mfg Industries
SAP MII The Flexible Connector Delivers Role-based Content and Context Combination of Data Access, Business Logic, Quality and Visualization Services, as well as Alerting, Metrics, KPIs
Upcoming Events
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