Performix Inc: Implementing MES in SAP Landscape
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Performix Inc: Implementing MES in SAP Landscape
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Implementing MES in SAP Landscape
Sham AfzalpurkarCEO, Performix Inc.
September 26th, 2006
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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
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Agenda
• Overview of MES• Justifying MES• Developing MES Strategy• MES Architecture• Integration Strategy• Implementation Plan• Lessons Learned
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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
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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
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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
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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
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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
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MES vendors offer solutions that overlap functionality offered by SAP
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Agenda
• Overview of MES• Justifying MES• Developing MES Strategy• MES Architecture• Integration Strategy• Implementation Plan• Lessons Learned
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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
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Justifying MES - Benefits
• Increases Operational Excellence
• Lower Operating Costs
• Asset Management
• Reduced Total Cost of Ownership
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Agenda
• Overview of MES• Justifying MES• Developing MES Strategy• MES Architecture• Integration Strategy• Implementation Plan• Lessons Learned
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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
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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
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Simple Discrete
Some PLCsMachines & Work CentersFixed Routes, No Lot SplittingOnly Ingredients Changes
ERP
DemandPlanning
Supply Chain Planning
ProductionPlanning
Cost Accounting
WarehouseManagement
MaintenanceManagement
MaterialManagement
Human ResourceManagement
Sales &Distribution
Detail Scheduling
Enterprise Performance Reporting
ProductionHistory
WIP MaterialManagement
PerformanceManagement
ResourceManagement
ProductionExecution
ProcessAnalysis
QualityManagement
Real-TimeMonitoring
Real-TimeExecution
Real-TimeSPC
Real-TimeControl
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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
Supply Chain Planning
ProductionPlanning
Cost Accounting
WarehouseManagement
MaintenanceManagement
MaterialManagement
Human ResourceManagement
Sales &Distribution
Enterprise Performance Reporting
Detail Scheduling
ProcessAnalysis
ProductionHistory
WIP MaterialManagement
ResourceManagement
ProductionExecution
QualityManagement
Aerospace and Automotive
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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
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
Semiconductor
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SCADA / PCSEquipment TrainsFlexible Connections
ERP
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
Pharmaceuticals & Specialty Chemicals
many shared resources, large recipes, many productsMES compliance, complex procedures
Detail Scheduling
PerformanceManagement
ProcessAnalysis
RecipeManagement
ProcessOptimization
ProductionHistory
WIP MaterialManagement
ResourceManagement
ProductionExecution
QualityManagement
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SCADA / PCSEquipment TrainsFixed Connections
Large number of control variables, real-time optimization
ERP
ProductionHistory
PerformanceManagement
ProcessAnalysis
QualityManagement
Real-TimeMonitoring
Real-TimeExecution
Real-TimeSPC
Real-TimeControl
ProcessOptimization
DemandPlanning
Supply Chain Planning
ProductionPlanning
Cost Accounting
WarehouseManagement
MaintenanceManagement
MaterialManagement
Human ResourceManagement
Sales &Distribution
Enterprise Performance Reporting
Oil & Gas and Bulk Chemicals
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MES Functionality
• Dispatching and Production• Resource Allocation• Quality Management• Data Collection• Process Management• Production Tracking and Genealogy• Document Control• Performance Analysis• Operational Detail Scheduling
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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
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Resource Allocation & Status
• Manage the resources directly associated with control and manufacturing.
Criteria Positioning
Manual & Simple Procedure SAP PP or PI
Manual & Automated MES
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Data Collection & Acquisition
Obtains operational production and parametric data associated with production equipment and processes. Provides real-time statuses of production equipment and processes.
Criteria Positioning
Discrete &/or low data volume SAP / PP or PP PI
High speed real time data collection or very high volume
MES
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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
.
Criteria Positioning
Manual data collection SAP QM
Real time measurements with simple statistics
MES / SAP xMII
Real time measurements with multi-variable analysis
MES / SAP xMII
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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.
Criteria Positioning
Manual SAP / PP or PPPI
Automated Systems MES
Complex Recipes MES
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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.
Criteria Positioning
Simple Recipe & Tracking SAP
Compliance/Traceability MES or xApp
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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
Criteria Positioning
Simple Manual & Automated Systems
SAP xMII
Complex Recipes or Advanced Analysis
MES + SAP XMII
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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
Criteria Positioning
Simple Discrete Processing with a Large Supply Chain
SAP APO PPDS
Complex, Very Large, Non-linear Recipes
SAP APO + MES or Consider xApp
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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
Criteria Positioning
Simple Work Flow SAP
Simple WF and Regulatory Compliance
SAP / Document Management System
Complex WF with Regulatory Compliance
SAP + MES+ Document Management
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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.
Criteria Positioning
Standard HR Functionality SAP HR
Training Compliance during execution
SAP/MES
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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.
Criteria Positioning
Standard PM functionality SAP Plant Maintenance
Real-time Condition Based Maintenance
SAP Plant Maintenance + MES
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Agenda
• Overview of MES• Justifying MES• Developing MES Strategy• MES Architecture• Integration Strategy• Implementation Plan• Lessons Learned
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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
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Agenda
• Overview of MES• Justifying MES• Developing MES Strategy• MES Architecture• Integration Strategy• Implementation Plan• Lessons Learned
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SAP MES Integration Options
• Use SAP xMII – Preferred
• Build your own XI integration
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• 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
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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
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Agenda
• Overview of MES• Justifying MES• Developing MES Strategy• MES Architecture• Integration Strategy• Implementation Plan• Lessons Learned
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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
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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
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Why Pilot?
• Enhance understanding of MES
• Determine how well current requirements fit into an MES
• Validate the Integration strategy
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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
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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
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0707Session Code: