SAP MII in a mass customization · PDF fileKPI MII – Realisation Source: Team Digital...

SAP MII in a mass
customization Business
Dr. Daniel de Sousa

Content
Overview of Business Segment & Business Process
Project Motivation & Solutions
Achieved Goals
Next Steps

Overview of Business
Segment & Process
Cara The Digital World in Dental Labs

Change in the Production of Dental Prosthetics
Impression Patient Model Wax-Up Casting Veneering
Until 2000: The traditional process dominates the market
Dentist Dental Lab Dentist
Source: Team Digital Prosthetics
BS Digital Prosthetics

Impression Patient Model Wax-Up Casting
2011ff: Complete digital workflows
CAD-Design CAM-Veneering Digital Impression CAM
Dentist
Dental Lab / Industry Dentist / Dental Lab
Veneering
Change in the Production of Dental Prosthetics

Heraeus CAD/CAM
(CARA)
Milled Zirconia / PMMA / NPM
frameworks for crowns and bridges
Laser Sintered NPM frameworks for
crowns and bridges (non-anatomic)
Product Application
Our Business Case CAD/CAM (CARA)

Insertion
Dentist
Finished
Prosthesis
Veneering
Dental Lab
Dental
Framework
CAM- Production
Scanning/ CAD
Heraeus
CAD-Data
CAD/CAM-Process
Production of Dental Prosthetics by CAD/CAM
(Central Manufacturing as of Today)
Dentist
Dental Model
Dental Lab
Impression
Preparation/ Impression
Patient Patient
Make-To-Order (batch size= 1)
Short lead-time (2 days)
Very high precision

CAM Data Generation/ Nesting
Order Inflow
Data Transfer
CAD- Construction
What are the Production Steps?
Scanning
Packaging/ Shipment
Quality Control 2
Sintering Quality Control 1
CNC- Milling
Dental Lab Production CAD/CAM
Production CAD/CAM
Zirconia

Shop Floor

Project Motivation &
Solutions

Step one: Transparency
Heterogeneous shop floor (milling, SLM, SLS, )
Wide band of material groups with different production steps
Interdisciplinary working in one process (Production, Customer Service Center, Logistics, )
Mass production of individualized products

Production Logistics (SAP MII)
Precise view of
all customer
orders along
the process
chain
Identification of
workload in the
different
process steps
Shop Floor
Integration
Identification of
bottlenecks

Heraeus Production Dashboard

Step two: TIME On time delivery
Motivation
Proactive intervention needed for potentially delayed orders
No real time surveillance for time critical orders (employee's gut feeling or singular analysis in SAP ERP)
process errors are recognized with a delay or to late
Interface errors between systems
lost orders in production
.
Mistakes happen quite seldom but have large impact on customer satisfaction
Hurdles Variable time for order reception vs. fixed time for shipment ( plus 2 days at 7pm)
Wide variety of products with different production methods
Goal: Implementation of an automized system for real time recognition of potentially
delayed orders

KPI MII Realisation
Order reception
10%
VNES 5%
ZNES 2%
BNES 6% Milling
20% QC1 10%
VSINT 2%
Sintering 30%
QC2 10%
Distribution 5%
Every Customer Order receives a time stamp
Production end date is a constant (2 working days after order is received/ 07pm)
Time based milestones are calculated per customer once received
Basis for calculation is
Production method, material group and an material number
For each material group there is a unique production process
For each material belonging to this group time based milestone exist (example):
Each milestone is monitored by SAP MII
If a milestone is not reached in time the order is visualized in SAP MII until the order is
finished or back on track
Working days / week ends and holidays are customizable by key users
Certain customer groups (internal customers) can be filtered
Monday
2:54 pm
Wedneday
07:00 pm
Monday
08:06 pm
Tuesday
02:51 am
Tuesday
12:15 pmr
Tuesday
05:40 pm
Wedneday
11:52 am
Wedneday
05:04 pm

KPI MII Visualization

Achieved Goals

All of the above and more
On time delivery rate of 99,5 % and rising steadily (goal 2011: 99,0 %)
reduction of scrap production due to threshold warning
Flexible and autonomous personnel planning Capacity is raised where it is needed without intervention of production
manager
Critical process errors can be tended tended to when they occur
Customer service agents can now actively inform customers of potential delays
Achieved goals.

Next Steps

UI optimization
SAP UI interaction in QC consumes 0,6 FT
Simple yes or no decision
Basis for the implementation is SAP MII
Planned for Dec. 2011
First Step is QC followed by rest of plant in 2012

SAP MII in a mass customization · PDF fileKPI MII – Realisation Source: Team Digital...

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