performix inc: implementing mes in sap landscape

Performix Inc: Implementing MES in SAP Landscape

Implementing MES in SAP Landscape

Sham AfzalpurkarCEO, Performix Inc.

September 26th, 2006

Introduction• Sham Afzalpurkar, CEO Performix Inc

• About Performix• A Manufacturing Execution Systems company• Developing xApps in MES space• Significant Supply Chain, Manufacturing Execution &Track/Trace experience• Focus on Pharmaceuticals, Process Industries and Hi Tech• Offices in Houston, Texas with development teams in India

Agenda

• Overview of MES• Justifying MES• Developing MES Strategy• MES Architecture• Integration Strategy• Implementation Plan• Lessons Learned

Why MES?

• In the last decade, ERP and SCM have NOT delivered the expected returns

• Focus on deploying MES solution to give visibility and flexibility and effectively manage supply chain

• Competition has forced quality products at lower cost• Integration of ERP and MES has been a challenge• Standards such ISA 95 provide the potential to simplify deployment

What is Manufacturing Execution System?

• Co-ordinate functions on the shop floor to optimize the plant activities

• Manufacturing Execution System provides effective integration between production processes and enterprise business systems.

• Layer of communication between business and control systems

MES

ERP

SHOP FOOR AUTOMATION

Components of MES

• Core• Material and Production Tracking • Material Handling and Production Procedures• Resource management and allocation• Production Dispatching• Data Collection

• Extensions• Compliance• Quality Assurance • Performance Analysis• Detail Scheduling • Document Management• Labor Management

What is ISA 95?

• Instrumentation, Systems, and Automation Society (ISA) Standard• Standard that defines how to link Enterprise and Controls systems using a

Manufacturing Execution Systems (MES) layer. This standard describes:• The MES Functionality • The Data base schema at the MES Level• The Messages between the Enterprise system and MES

What is B2MML?• The World Batch Forum (WBF) has published XML schemas based on the S95 Model - B2MML

(Business to Manufacturing Markup “Hypertext” Language)

• B2MML-V0201-Common.xls• B2MML-V0201-Personnel.xls• B2MML-V0201-Equipment.xls• B2MML-V0201-Material.xls• B2MML-V0201-Maintenance.xls• B2MML-V0201-ProcessSegment.xls• B2MML-V0201-ProductionDefinition.xls• B2MML-V0201-ProductionCapability.xls• B2MML-V0201-ProducitonPerformance.xls• B2MML-V0201-ProductionSchedule.xls

MES vendors offer solutions that overlap functionality offered by SAP

Agenda


Justifying MES – Business Drivers

• Visibility of data globally• Standard processes

• Enable benchmarking and best practices

• Consistent Documentation • Resource Utilization• Accurate and consistent KPI• Seamless Integration

Justifying MES - Benefits

• Increases Operational Excellence

• Lower Operating Costs

• Asset Management

• Reduced Total Cost of Ownership

Agenda


Manufacturing Assessment & Planning

• What are the business drivers?

• What are the organizational and process related issues?

• What should be done first – aligning manufacturing strategy with business strategy

Business Functions (S95)

Real-TimeMonitoring

Real-TimeExecution

Real-TimeSPC

Real-TimeControl

DemandPlanning

Supply Chain Planning

ProductionPlanning

Cost Accounting

WarehouseManagement

MaintenanceManagement

MaterialManagement

Human ResourceManagement

Sales &Distribution

Enterprise Performance Reporting

Detail Scheduling

PerformanceManagement

ProcessAnalysis

RecipeManagement

ProcessOptimization

ProductionHistory

WIP MaterialManagement

ResourceManagement

ProductionExecution

QualityManagement

Level 4BusinessPlanning &Logistics

Level 3ManufacturingOperations

Level 2Plant FloorControl

Simple Discrete

Some PLCsMachines & Work CentersFixed Routes, No Lot SplittingOnly Ingredients Changes

ERP

DemandPlanning


ProductionPlanning

Cost Accounting

WarehouseManagement


MaterialManagement


Sales &Distribution

Detail Scheduling


ProductionHistory



ResourceManagement

ProductionExecution

ProcessAnalysis

QualityManagement

Real-TimeMonitoring

Real-TimeExecution

Real-TimeSPC

Real-TimeControl

http://www.sap.com/index.epx

Complex Discrete

MES Thousands of parts, complex procedures, many products

Some PLCsMachines & Work CentersProduction Lines

ERP

Real-TimeMonitoring

Real-TimeExecution

Real-TimeSPC

Real-TimeControl

DemandPlanning


ProductionPlanning

Cost Accounting

WarehouseManagement


MaterialManagement


Sales &Distribution


Detail Scheduling

ProcessAnalysis

ProductionHistory


ResourceManagement

ProductionExecution

QualityManagement

Aerospace and Automotive

many shared resources, complex routing, many productsMES thousands of parts, complex procedures

Some PLCsMachines & Work CentersProduction Lines

ERP

Real-TimeMonitoring

Real-TimeExecution

Real-TimeSPC

Real-TimeControl

DemandPlanning


ProductionPlanning

Cost Accounting

WarehouseManagement


MaterialManagement


Sales &Distribution


Detail Scheduling


ProcessAnalysis

RecipeManagement

ProcessOptimization

ProductionHistory


ResourceManagement

ProductionExecution

QualityManagement

Semiconductor

SCADA / PCSEquipment TrainsFlexible Connections

ERP

Real-TimeMonitoring

Real-TimeExecution

Real-TimeSPC

Real-TimeControl

DemandPlanning


ProductionPlanning

Cost Accounting

WarehouseManagement


MaterialManagement


Sales &Distribution


Pharmaceuticals & Specialty Chemicals

many shared resources, large recipes, many productsMES compliance, complex procedures

Detail Scheduling


ProcessAnalysis

RecipeManagement

ProcessOptimization

ProductionHistory


ResourceManagement

ProductionExecution

QualityManagement

SCADA / PCSEquipment TrainsFixed Connections

Large number of control variables, real-time optimization

ERP

ProductionHistory


ProcessAnalysis

QualityManagement

Real-TimeMonitoring

Real-TimeExecution

Real-TimeSPC

Real-TimeControl

ProcessOptimization

DemandPlanning


ProductionPlanning

Cost Accounting

WarehouseManagement


MaterialManagement


Sales &Distribution


Oil & Gas and Bulk Chemicals

MES Functionality

• Dispatching and Production• Resource Allocation• Quality Management• Data Collection• Process Management• Production Tracking and Genealogy• Document Control• Performance Analysis• Operational Detail Scheduling

Dispatching Production

• Manages the flow of production in the form of jobs, orders, batches, lots and work orders by dispatching production to specific equipment and personnel. Includes information that is presented in the sequence in which the work needs to be done.

Criteria Positioning

Simple Recipe & Tracking SAP / PP or PPPI and APO

Complex Recipes MES

Complex Lot Management Consider xApp

Resource Allocation & Status

• Manage the resources directly associated with control and manufacturing.


Manual & Simple Procedure SAP PP or PI

Manual & Automated MES

Data Collection & Acquisition

Obtains operational production and parametric data associated with production equipment and processes. Provides real-time statuses of production equipment and processes.


Discrete &/or low data volume SAP / PP or PP PI

High speed real time data collection or very high volume

MES

Quality Management

• Provides real-time measurements collected form manufacturing to assure proper product quality control and to identify problems requiring attention. Includes SPC / SQC tracking and management of offline inspection operations

.


Manual data collection SAP QM

Real time measurements with simple statistics

MES / SAP xMII

Real time measurements with multi-variable analysis

MES / SAP xMII

Process Management

• Monitors production and either automatically corrects or provides decision support to operators for correcting and improving in-process functions. It may include alarm management to handle process deviations.


Manual SAP / PP or PPPI

Automated Systems MES

Complex Recipes MES

Production Tracking & Genealogy

• Provides status of production and disposition of work. Status information may include personnel, materials used, current production conditions. Includes recording of production information to allow forward and backward traceability.


Simple Recipe & Tracking SAP

Compliance/Traceability MES or xApp

Performance Analysis

• Provides real-time reporting of actual manufacturing operations results along with comparisons to past history and expected results. Performance results include resource utilization, resource availability, cycle time, conformance to schedule and standards. May include SPC / SQC analysis


Simple Manual & Automated Systems

SAP xMII

Complex Recipes or Advanced Analysis

MES + SAP XMII

Operations & Detailed Scheduling

• Provides sequencing based on priorities, attributes, characteristics and production rules. It is finite and it recognizes alternative and overlapping operations to calculate timing of equipment loading


Simple Discrete Processing with a Large Supply Chain

SAP APO PPDS

Complex, Very Large, Non-linear Recipes

SAP APO + MES or Consider xApp

Document Control

• Control records and forms that must be maintained with the production unit. Includes work instructions, recipes, drawings, standard operating procedures (SOP), batch records, shift to shift communication. It sends instructions down to operations and device controls


Simple Work Flow SAP

Simple WF and Regulatory Compliance

SAP / Document Management System

Complex WF with Regulatory Compliance

SAP + MES+ Document Management

Labor Management

Provides status of personnel. Includes time and attendance, certification tracking, as well as preparation work as basis for activity–based costing. May interact with resource allocation for optimal assignments.


Standard HR Functionality SAP HR

Training Compliance during execution

SAP/MES

Maintenance Management

• Functionality for maintaining equipment and tools. Ensures equipment and tools availability for manufacturing. May also include scheduling for periodic or preventive maintenance. Maintains history of past events to aid in diagnosing problems.


Standard PM functionality SAP Plant Maintenance

Real-time Condition Based Maintenance

SAP Plant Maintenance + MES

Agenda


SAP R/3

Intelligence Dashboard

Production Planning

QualityManagement

Plant Maintenance

MaterialsManagement

SNP PPDS GlobalATP

Demand Planning

OPC

Integration

xApps/Composite Apps

Human Resources

APO

xMII

S95Master & Transaction Data

BW

MES

SAP MES Architecture

LIMS Historian PAT SCADA Devices Doc Mgmt

Agenda


SAP MES Integration Options

• Use SAP xMII – Preferred

• Build your own XI integration

• SAP xMII enables real-time transactional integration between plant floor and enterprise (SAP ERP) systems out-of-the box thru:

• Universal Connectivity to the data, functionality and processes of existing plant floor systems and SAP

• Advanced composite application capabilities for creating automated events, KPIs and alerts, and new manufacturing business processes

• Synchronization of SAP ERP with real-time Plant Floor Systems and Processes using proprietary and standards-compliant messages and workflows

• Data Services that provide a foundation for Manufacturing Synchronization and Intelligence

Enterprise

Plant Floor

SAP NETWEAVER

Oth

er S

AP

Bu

s.

So

lu t

ion

s

S

AP

BI

SAP Manufacturing (mySAP ERP)

Manufacturing Intelligence Dashboards

SAP xMII

Manufacturing Integration

Manufacturing Intelligence

XI

SAP MES Integration Using xMII

MES Integration with SAP – Using xMII

PEOPLE

INFORMATION

SAP R/3, SCM, BW…

SAP Enterprise Portal

Integration

SAP xMII

= SAP

Shopfloor Application – ANSI/ISA-95 Compliance

B2MM

L Msg

= 3rd Party Application

Use xMII Integration capabilities if S95 Non Compliant

Agenda


MES Deployment Strategy

• Understand the problem you are trying to solve• The business drivers

• How you deploy has impact on cost and scope• Integration with Process Control and other applications• Change in the business processes• Facility readiness

Start Ramp-up

Design MES Architecture

Design MES Architecture

AssessmentAssessment

Develop DeploymentPlan

Develop DeploymentPlan

PilotPilot

Map MES Requirements

Map MES Requirements

Analyze manufacturing processes and develop MES

requirements

Identify gapsDetail plan for pilot and

rollout

Roll OutRoll Out

Map requirements with SAP Functionality.

Develop global processes, Integration touch points

Review Pilot results

Why Pilot?

• Enhance understanding of MES

• Determine how well current requirements fit into an MES

• Validate the Integration strategy

Scope of Pilot

• Should cover end to end processes• Team

• Project Lead• SAP Expertise – MM/PP/PI, QM, APO• Automation Expertise• QA/QC• Integration/xMII • Plant Floor

• Timeline• About 3-4 months

Take Aways

• There is an overlap of functionality offered by SAP and MES vendors• Perform detail MES requirement mapping with SAP functionality• Make the decision up front where the functionality resides (SAP or MES)

• In many cases SAP + xMII + xApp could meet your requirements

• For complex processes, compliance and regulatory requirements, consider third party MES solutions

• xMII is the preferred Integration solution in the SAP landscape• Start with an end to end pilot

0707Session Code:

performix inc: implementing mes in sap landscape

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