SAP Digital Manufacturing Supporting the Intelligent ... · Distributed Manufacturing....

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PUBLIC

John HarrisonOctober, 2018

SAP Digital ManufacturingSupporting the Intelligent Enterprise


2PUBLIC© 2018 SAP SE or an SAP affiliate company. All rights reserved. ǀ

2 Key industry trends Shaping the industrial / manufacturing landscape

SAP Digital Manufacturing

SAP Digital Manufacturing in S/4HANA

Convergence of on-premise and cloud Introduction of the SAP Digital Manufacturing Cloud

Agenda


2 Key industry trends



Contextualized Data The accuracy of a model is only as good as the data feeding it

Standardization of Predictive Models

In standardizing the foundation of data complex generic and industry specific models are easy to support and expand

KPI StandardizationPre-delivered industry standard KPIs with flexibility to extend/create new KPIs

Previously Undetected Correlations and

Patterns

Root Cause AnalysisPattern detectionPrescriptive Suggestions

Complex Analytics Require a Strong FoundationConceptual Data Model for Analytics

Standard & Custom KPIs and Metric Calculations

Industrial Event, Meter, and Analog Data

Predictive Models

Unstructured Machine Learning

0123

http://www.tylervigen.com/spurious-correlations

http://www.tylervigen.com/spurious-correlations



A Shifting Landscape: IT/OT Convergence Becomes IoT/OT Convergence

Step #1 – IT Provisions Device

IoT Services

1. Device Registration

2. Firmware Mgmt.

3. Device is now Active

Step #2 – Model Device in the context of a process where multiple new and existing systems are present

SAP Digital Mfg. Cloud (S95 & S88)

SAP Plant Connectivity

SCADA Historian

1. Manage Connectivity and application context including meter, event & streaming data

2. M2M processes & control

IoT Edge Gateway

IT Provisioned Devices

OPC-UA

Handover Details to Applications

SAP Digital Mfg. Suite

• IT professionals are no longer bringing software only, they have hardware (IoT) now

• They still require support from local teams

• Local teams still need IT to support them and their needs at the ‘Fog’ layer

• IIoT is not new in the industrial/manufacturing industries, but the processes to manage it in the context of the business applications is.

Key Points

https://blogs.sap.com/2018/05/22/is-itot-convergence-dead

https://blogs.sap.com/2018/05/22/is-itot-convergence-dead



A Shifting Landscape: The Inverse Historian

• Local management of large data persistence is no longer required

• Central & local teams provide joint administration

• Central & local teams share usage of the same common data catalog

• Centralized compute power and extensibility ensure that the infrastructure is managed and flexible to meet the changing business needs

• Including cloud software updates

Key PointsDigital

Manufacturing Cloud

Asset Central

ML APIs

SAP Manufacturing Suite

ERP DataAsset Hierarchy

Event & Historical Data

{

SAP Industrial Edge


(PCo)

SAP Edge Services (Includes DEP)

IT Policy, Security & Management

SAP Edge Gateway

Application Management of SAP Industrial Edge

IoT Service 4.0

Connection Details & Mgmt.

SCADA, DCS & Historians

IT Provisioned Devices

Application Data (Event & Streaming)

https://blogs.sap.com/2018/05/29/the-inverse-historian-historian-1

https://blogs.sap.com/2018/05/29/the-inverse-historian-historian-1




DESIGN SOURCE DELIVER SERVICEMAKE

Connect Top Floor and Shop Floor

Digital Manufacturing wires the world of machines with business processes Shop Floor to Top Floor (vertical) Machine to Machine (horizontal) End to End Integration Business Partners Easy Connectivity

Build on an open IoT ready platform supporting Industry 4.0 manufacturing Following the OPC UA Standards Enabling a manufacturing network Connecting partners along the supply chain With flexible Deployment Options

PartnerConnectivity

CustomerConnectivity

SAPConnectivity

MachineOrchestration

Predictive Quality

Distributed Manufacturing

Manufacturing Engineering

Manufacturing Planning Manufacturing Execution Predictive

Maintenance

Digital Manufacturing Insights



SAP Manufacturing Execution SuiteHighlights

Integration Excellence ERP integration “out of the

box” Easy integration with shop-

floor automation layer Lot size 1 and mass

customization

Usability Excellence Pure browser-based UI Role-specific access and

personalized dashboards for operators

Process Excellence Unit-level tracking & tracing Comprehensive

nonconformance management

Process interlocking High performance with SAP

HANA

Flexibility & Agility Excellence High flexibility and extensibility Pure SOA-based architecture Flexible production process modeling

without additional programming



Industry 4.0 enhanced scenarios to: Connect, monitor, and tightly control your

manufacturing operations Control the production of every single unit to reduce

the cost of quality 3D non-conformance management, from in-line

sampling to visual testing and repair

Integration excellence to: Leverage seamless, out-of-the-box SAP ERP and

S/4 HANA integration Extended integration Extended Warehouse

Management (EWM), Digital Manufacturing Insights (DMI) or Integration with Asset Intelligence Network (AIN)

Performance: High performance manufacturing platform Flexibility and extensibility for operators and machine

process control

SAP Manufacturing Execution Suite (ME/MII/PCo)


SAP Digital Manufacturing in S/4HANA



Manufacturing planning cockpit Comprising a comprehensive planning environment Material requirements planning Production planning Capacity planning

Advanced planning capabilities Heuristics and optimizers for finite planning & scheduling Industry specific planning logic

(e.g. block planning, model mix planning) Decision support Simulation and ‘what-if’ analysis

Comprehensive multi-level planning runs Covering all kinds of materials and planning

methods in one run Leveraging new planning approaches

− e.g. Demand-driven replenishment: stock-level management

Digital Manufacturing in S/4HANASAP S/4HANA Manufacturing for planning and scheduling



Manufacturing Engineering Cockpit For comprehensive manufacturing process planning comprising: BOM / routing Factory layout / machine model

Covering all master data relevant for orchestration and execution, such as: Operations / activities Component assignments Lead times and processing times Work instructions Data collections and inspection characteristics Tools

Manufacturing Change Management Analyzing engineering changes Identifying affected BOMs, routings, production orders Orchestrating consistent modifications and release Controlling work flows (e.g. for sign offs) planning

Digital Manufacturing in S/4HANAS/4 HANA Manufacturing for Manufacturing Engineering



Digital Manufacturing in S/4HANAS/4 HANA Manufacturing for Extended Production Operations

Supervisor Cockpit Monitoring of all shop floor

operations with automatic issue detection, root cause analysis and decision support.

Operation Release Management Comprehensive feasibility

checks e.g. on component, machine and tool availability.

Adaptive Worker UIs Includes work instructions,

collecting data and handling of exception cases

Shop Floor Item Control Tracking and tracing of

individual parts and part specific genealogy


Convergence of on-premise and cloudIntroducing SAP Digital Manufacturing Cloud



Digital Manufacturing PortfolioIndustry 4.0 in the Cloud and On-Premise

SAP S/4HANA for Production Engineering &

Operations

SAP Digital Manufacturing Cloud

Manufacturing Network

Manufacturing Execution


SAP Manufacturing Integration and

Intelligence

SAP Manufacturing Execution

Manufacturing Insights

New digital manufacturing components in the cloud to enable digital transformation

Continued innovation in the on-premise offerings Extensions of S/4HANA Manufacturing

On-PremiseCloud


SAP Digital Manufacturing Cloud –Manufacturing Insights



SAP Digital Manufacturing Cloud – Manufacturing InsightsDigital systems for measurement and control in combination with real-time business context

Analyze using standardized key performance indicators (KPI) to assess performance across locations

Perform root cause analysis at any level – global, plant or individual work center to assess for systematic failures

Define your own dashboards or adapt KPIs and thresholds to customize the solution for yourself or your entire organization

Utilize harmonized data which was acquired from disparate sources including non SAP sources

Build your own KPI with your individual math

Operationalization of machine learning for quality defects detection

Using holistic view on the production process by integrating IT data – product genealogy – and OT data – high frequency machine data

Root Cause

Analysis

AlertManagement

Enterprise Hierarchy

Personalized KPIs

IndividualizedDashboard

Design

Overall Equipment

EffectivenessInsights

Manufacturing Insights

KeyPerformance

Indicators

Predictive Modelling

Predictive Quality

Machine Models

Machine Data

Key capabilities



Key capabilities

SAP Digital Manufacturing Cloud – Manufacturing InsightsProduct description: A centralized, cloud-based, data-driven manufacturing performance management solution that enables key stakeholders of manufacturing operations to take tactical and strategic decisions to achieve best-in-class manufacturing performance

Analysis of manufacturing performance within and across manufacturing plants of an enterprise

Data acquisition from multiple disparate manufacturing applications and harmonization of manufacturing data with SAP ERP and SAP ME

Preconfigured industry-standard manufacturing key performance indicators (KPIs) e.g. Defects / unit(DPU), First Pass Yield, OEE etc.

Unified Manufacturing Modeler to customize own KPIs using manufacturing data with SAP ERP and SAP ME

Advanced algorithms for root cause analysis of quality defects and pattern detection, and prescriptive suggestions for continuous manufacturing performance improvement

Contextualize sensor data with KPIs with remote connectivity to Plant Connectivity

Global Analytics Multiplant


SAP Digital Manufacturing Cloud - Overall Equipment Effectiveness (OEE)



SAP MII for Overall Equipment EffectivenessSAP MII delivered standard content

» Rich Standard Content on top of MII for simple order execution along with calculating of key OEE KPIs.

» Bi-Direction top-floor to shop floor integration. Ability to download production/process order, collect production, rework, waste, standard value key, raw material etc. and post it back to ERP system.

» Capture the root causes for downtime, efficiency loss and poor quality. Facilitates analysis and corrective action at the plant level and across plants

» Analyze real-time information on OEE, Availability, Performance and Quality on various hierarchy levels along with business context

» Operator friendly UI design Responsive and device friendly UI, State-of-the-art technologies

» Automation Support of Green field and Brown field factories Support of Manual, Semi-automatic and Automatic Production environment



SAP Manufacturing Integration & Intelligence and Overall Equipment EffectivenessGlobal, Multi-Site Analysis for E2E Transparency

Description Analysis and real-time information on OEE, availability, performance and quality on various

hierarchy levels Local data collection and Analysis in MII Global, multi-plant analysis via SAP HANA Combination of shop floor data with enterprise information

Key Benefits Real-time monitoring Cross plant analysis / best practice Analysis of shop floor with top floor context



SAP Digital Manufacturing – Management of OEE @ ScaleEnsure Reporting Consistency & Scale

SAP MII (Private Cloud Or On-Premise)

SAP S/4 (ECC 6)(Private Cloud Or On-Premise)

SAP Digital Manufacturing Cloud for Manufacturing Insights(Public Cloud)

Plant 1 Plant 2 Plant N


SAP Digital Manufacturing Cloud -Manufacturing Execution



SAP Digital Manufacturing Cloud - Manufacturing ExecutionOrchestrate and control the shop floor

Implement top-floor to shop-floor scenarios to achieve rapid return-on-investment through out-of-the-box integration to SAP solutions

Utilize intuitive user interfaces (UI) for production operators and transform to paperless production

Dispatch and sequence operations to reflect the real world in the short term

Monitor the entire manufacturing process to optimize resources and execution

React quickly to unexpected events

Includes all of Digital Manufacturing Cloud for insights features

LaborManagement

Plant Connectivity

SAP ERP Integration

ProductionOperator Dashboard

Designer (POD)

WIP Tracking

ResourceOrchestration& Dispatching

Quality and Nonconformance

Overall Equipment

Effectiveness

Machine Orchestration

Skills

Work Instructions

Shift andMessage Boards

Data Collection

Manufacturing Execution

Key capabilities



Create custom dashboards for your users: Configure for desktop or mobile devices Role-specific user experience Drag and drop feature with predefined plug-ins

to simplify POD creation Customize the layout of the user interface (UI)

and preview a design in real time to enable the user to visualize how it will be presented to the production operators which is available for production operators to report execution data

Configure actions that should be available for production operators

Define commonly used lists such as order queues and worklists which can be sorted

SAP Digital Manufacturing Cloud - Manufacturing ExecutionProduction operator dashboard (POD) designer



SAP Digital Manufacturing Cloud - Manufacturing ExecutionMaster data management

Maintain master data to be used during execution: Materials Bill of Materials (BoMs) Resources Work centers Operation activities Routings Shifts Work instructions



Create routings to outline the production flow

Graphical engine to manage routing

Select the relevant operations and actions and sequence them based on the production flow with drag and drop feature

Enable different versions with version control

During the production execution, the shop floor control flow from one operation to another is decided based on the configured routing

Out-of-the-box integration with SAP S/4HANA (on-premise) and SAP ERP

SAP Digital Manufacturing Cloud - Manufacturing ExecutionManage routing



In order to collect data manually or through automation during execution, you set up the following:

Create the data collection parameters by groups and attach to the appropriate object

Define parameter types such as numeric, text, Boolean and its limits

Production operators report this data from the POD during the production execution process.

The parameters can also be reported via machine automation.

SAP Digital Manufacturing Cloud - Manufacturing ExecutionManage data collection



Create orders, manage statuses and release orders for execution

Out-of-the-box integration with production orders from SAP S/4HANA (on premise) and SAP ERP

SAP Digital Manufacturing Cloud - Manufacturing ExecutionManage and release orders



Production operators use the configurable PODs to report execution data– Start and completion of orders

through the routing operation activities

– Recording of data collection, non-conformance

– Recording of OEE losses– Recording of the production

activity performed against the order

View work instructions relevant for the order and operation being executed

Enforcement of routing flow including dynamic routing decisions

SAP Digital Manufacturing Cloud - Manufacturing ExecutionCollect execution data



Optimize machine efficiency for the shop floor with Overall Equipment Effectiveness (OEE)

Real-time visibility over OEE and related KPIs

Integrated OEE POD to collect OEE losses and reasons

Simplified user interface allows production operators to report machine status change with ease

Detailed OEE insights and root cause analysis with manufacturing insights

SAP Digital Manufacturing Cloud - Manufacturing ExecutionOverall Equipment Effectiveness (OEE)



SAP Digital Manufacturing Cloud - Manufacturing ExecutionOrchestrate and control the shop floor

Monitor the entire manufacturing process to optimize resources and execution

Role-specific Fiori and operator dashboards

Redesigned Production Operator Dashboard is fully configurable, supports drag/drop, preview

Operator OEE dashboards to monitor OEE and manage downtime events.

Integrated Resource Orchestration to manage shop floor work flow and labor assignments

Automation interfaces to provide for shop floor driven manufacturing events and data collection

Key capabilities Global Execution Multiplant



Production dispatching and monitoring

and Labor scheduling

Monitor production events and production progress

Schedule labor

Production Supervisor

Create the work load for the work centers

Enables the production supervisor or team lead to assign shifts to the workers s/he is responsible for; usually done for the complete year or several months

Assign the work center to personnel and shift – if certain workers are not available, then can assign the unavailability of the person for the corresponding day or week

Assignments are considered during dispatching in the Gantt Chart of the scheduling and dispatching app

SAP Digital Manufacturing Cloud - Manufacturing ExecutionResource Orchestration - schedule labor






Schedule labor



Overview of all operations belonging to an order with the order view

Monitor production progress at a glance

Missing personnel

Production progress

Overload situation

Machinebreakdown

High priorityorders

Order viewProduction progress

SAP Digital Manufacturing Cloud - Manufacturing ExecutionResource Orchestration - monitor production events and production progress






Schedule labor



Create workload via drag and drop; scheduling mode and direction are considered along with working and non-working times

Quickly identify and react to bottleneck situations with intuitive visualization of capacity overload situations and resource statuses

SAP Digital Manufacturing Cloud - Manufacturing ExecutionResource Orchestration - create the work load for the work centers


SAP Digital Manufacturing Cloud -Predictive Quality



SAP Digital Manufacturing Cloud - Predictive QualityPredictive insights to ensure consistent product quality

Predictive model scoring

Predictivealerts

Defect detectionalgorithm

Create and manage

predictive model

Equipmentanalysis

Materialcharacteristic

analysis

Predictive Quality Vendor qualityanalysis

One integrated framework to deliver predictive/prescriptive manufacturing capabilities

Acquire IT/OT data to build and capture all the parameters in manufacturing operations

Intuitive workbench to analyze and correlate multi-tier data related to 3Ms (man, machine, and material) of manufacturing

Operationalize predictive model building and model life cycle management

Near real-time evaluation of predictive models and trigger corrective actions by utilizing machine learning capabilities of the underlying platform

Near real-time prediction of quality defect in a manufactured product using machine learning model which is trained on historical product genealogy data acquired from various manufacturing applications such as SAP ERP, SAP S/4HANA and SAP ME

Key capabilitiesKey capabilities



Process engineer to choose IT/OT parameters from multi-tier data which is replicated from various source systems –to analyze influence of selected IT/OT parameter to KPI

Possible selections– Raw material (RM)/semi

finished (SF) material from BOM hierarchy

– RM/SF characteristics from ERP or SAP ME

– Process parameters based on the route operations/work center/resource/machine tag combination

SAP Digital Manufacturing Cloud - Predictive QualityAnalytical data set – Selecting IT-OT data for analysis



SAP Digital Manufacturing Cloud - Predictive QualityData stratification and analytics (1/3)

Analyze contribution of various IT-OT data selected in ‘analytical data model’ using descriptive analytics

View KPI value and KPI trend based on historic data

Analyze KPI value by production order or manufactured units(batch, serial number) as applicable

Segments to categorize production orders or produced units to ‘good’, ‘average’ and ‘worst’ categories

Analysis shows association of production route, BOM, resource, operator, process parameter to different category of POs or units



Chart shows association of resources and operators with the various POs and production units which are part of different segment




Analyze influence of material characteristics and material supplied by various vendors




Real time monitor helps production operator to get the near real time view of predictive model results

Based on the model evaluation result, operator can take corrective actions

SAP Digital Manufacturing Cloud - Predictive QualityMonitoring


SAP Digital Manufacturing Cloud -Manufacturing Network



SAP Digital Manufacturing Cloud - Manufacturing NetworkManufacturing Network enables distributed manufacturing operations

IP protection and Quality

Enforcement

Personalize Network

Ordering and

Billing

Parts Analysis

ServiceProviders and

Suppliers

Partner Extensibility

Design Collaboration

SAP Ariba, ERP, S/4HANA Integration


Key capabilities

Ability to add design data, quality criteria and manufacturing requirements to RFQ discussions

Part analysis to identify parts suitable for 3D printing

Review network service providers to determine potential partners

Individualize your network to achieve best results

Extend capabilities through integration of SW partners, e.g. for special IP protection needs and royalty scenarios

Business process integration with SAP solutions (e.g. SAP Ariba, S/4HANA, partner solutions, supplier systems, etc.)



SAP Digital Manufacturing Cloud - Manufacturing Network

Collaboration between customers and service providers on design optimization, quality and pricing

Technical and economical part assessment by customers

Integration with SAP S/4HANA for sourcing and procurement

Service offering advertisement by service providers

Extensibility to enable scenarios specific to domains, customers or service providers.

Integrates with Ariba Sourcing and the Ariba® Network, enabling manufacturers (buyers), suppliers and service providers to connect and collaborate across the entire manufacturing process


Customer Service bureaus

Product Description: provides a cloud-based collaborative platform that connects customers with (additive) manufacturing service providers, e.g. suppliers of 3D printing services, material providers, original equipment manufacturers (OEM), and technical certification companies

Key capabilities


Contact information:

John HarrisonIBU Chemical+1 416 505 [email protected]

Thank you.

SAP Digital Manufacturing Supporting the Intelligent ... · Distributed Manufacturing....

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