2006+xsteps

Manufacturing Execution Steps Overview

<Jürgen Wettengl>

<SAP AG>

SAP AG 2006, RKT for <Manufacturing – Execution Steps>, <> 2

Prerequisites

Required:

SAP R/3 basic knowledge in Process-Order Processing.

Recommended:

SAP R/3 knowledge in Process Management

SAP R/3 knowledge: Production Instruction Sheets

SAP AG 2006, RKT for <Manufacturing – Execution Steps>, <> 3

Agenda <Manufacturing – Execution Steps>

How to set up and use Execution Steps

Introduction

Summary

Solution : Manufacturing – Execution Steps

SAP AG 2006, RKT for <Manufacturing – Execution Steps>, <> 4

Supply

Chain

Hub

NetworkNetwork

Supplier

Partner Partner

Customer

Direct

Procurement

Source Deliver

Order

Fulfillment

Make

Manufacturing

Supply Chain Design

Strategize

Demand and

Supply Planning

Plan

Supply Chain Performance Management

Measure

Supply Chain Event Management

Track

Su

pp

ly C

hain

Co

llab

ora

tion

Co

llab

ora

te

Su

pp

ly C

hain

Co

llab

ora

tio

n

Co

llab

ora

te

Supply

Chain

Hub

Manufacturing – embedded solution

SAP AG 2006, RKT for <Manufacturing – Execution Steps>, <> 5

Marketing &

Sales Services

2nd

Tier

Supplier

2nd

Tier

Supplier

1st Tier

Supplier

End

ConsumerR&D Services

Service &

Maintenance

3PL

Service

Provider

Manufacturing - Integral Part of the Supply Network

Plant

Materials flow Information flow

Warehousing

Service

Provider

3PL

Service

Provider

Retailer

Manufacturing is the Heart of the Supply Network and is Central to Every

Business Dimension

SAP AG 2006, RKT for <Manufacturing – Execution Steps>, <> 6

Flexible and dynamic Execution of the Production Process

Manufacturing Execution - Goals

Reduced workload and maintenance effort by providing reusable methods and parameters (Execution Steps)

Provide a personalized work environment for fast and convenient access to different applications and services for plant personal (e.g. Shift Manager and Process Operator)

Flexibility and speed through dynamic, event-driven Production Instruction Sheets (PI-Sheets) with conditional logic

SAP AG 2006, RKT for <Manufacturing – Execution Steps>, <> 7

The Challenge

Master Recipe

Process

Instructions

Standard Xstep

Repository

Process Order

Process

Instructions

External System

Production Instruction Sheet

Copy

or

Reference

SAP AG 2006, RKT for <Manufacturing – Execution Steps>, <> 8

Agenda <Manufacturing – Execution Steps>

How to set up and use Execution Steps

Introduction

Summary

Solution : Manufacturing – Execution Steps

SAP AG 2006, RKT for <Manufacturing – Execution Steps>, <> 9

Manufacturing – Execution Steps

Execution Steps

Repository for standardized Execution Steps and Recipe

building blocks

Can be used by making a reference to them or

copying them

Flexible change management (versioning, approval

procedures, classical change management)

Basis for decoupling execution functions from PP-PI

(Master Recipe, Process Order)

Easy-to-use editor

Test and simulation capabilities

P

SAP AG 2006, RKT for <Manufacturing – Execution Steps>, <> 10

The Solution

Master Recipe Process Order

Reactor 1

Control Recipe

PI Sheet

PI Sheet /

Control Recipe

OPC

Execution Step

Repository

SXS

SXS: Standard XStep

XS XS

SAP AG 2006, RKT for <Manufacturing – Execution Steps>, <> 11

Business Processes Supported

Execution steps can be used in process industries:

For the creation of the PI sheet from the process instructions

contained within the process order

To control the creation of confirmations and process

messages in the PI sheet; for example batch data, goods

movements, and quality data

For the data exchange between the SAP R/3 system and

external control systems based on the industry standard OPC

or the PI-PCS interface

SAP AG 2006, RKT for <Manufacturing – Execution Steps>, <> 12

Production Instruction Sheet (PI Sheet) - Example

Generated

Material list

Soft logon/

logoff

Digital

Signature

Confirmations of

Material

Consumpions

Instructions for

Operator

Browser based

PI-Sheet

Adaptable Layout

Nested Sheets

Automated processes

Adaptable for specific

industry needs

SAP AG 2006, RKT for <Manufacturing – Execution Steps>, <> 13

Easy to use X-Step Editor

Komponenten

XS

XS

PA

PV

MS

I

CPV

PV

XS

XS

XS

XS

Semantic Check: Meldungen .................................... Suchfunktion: Ergebnisliste

Prozeßmeldungen

Prozeßvorgaben

Empfänger

Parameter

Bewertungssymbole

Generierungsumfänge

Standardschritte

Anwendungskontext

I

Herstellanweisung

Externe Systeme

Signatur

Simulation Test Prüfung Suche Im/Export

XS

XS

PA

PV

MS

I

CPV

PV

XS

XS

XS

XS

Semantic Check: Meldungen .................................... Suchfunktion: Ergebnisliste

AktualisierenDefault StylesheetSimulation der Oberfläche mit

Simulation Test Prüfung Suche Im/Export

Visualisation of Process

Instructions

Test and Simulation

Capabilities

Easy linking to Applications

Drag & Drop

SAP AG 2006, RKT for <Manufacturing – Execution Steps>, <> 14

Execution Steps for Mixing Tank &1

Check Mixing Tank &1

Fill mixing tank &1 with &2 liter

Heat tank &1 to &3 temperature

Discharge tank &1 automatically

Tank &1 discharge manually

Execution Steps - Example

SAP AG 2006, RKT for <Manufacturing – Execution Steps>, <> 15

Agenda <Manufacturing – Execution Steps>

How to set up and use Execution Steps

Introduction

Summary

Solution : Manufacturing – Execution Steps

SAP AG 2006, RKT for <Manufacturing – Execution Steps>, <> 16

Definitions

XSteps

Standard XSteps

XStep editor

Standard XStep repository

(SXS repository)

SAP AG 2006, RKT for <Manufacturing – Execution Steps>, <> 17

Execution Steps - Process

Create XStep Tree

XStep

Example

PI Sheet

Carry Out Check

Carry Out Simulation

Release VersionCan be copied or referenced:

- Master Recipe

- Process Order

Repository

XStep

Reference

SAP AG 2006, RKT for <Manufacturing – Execution Steps>, <> 18

Creating a Standard XStep for a PI-Sheet

Here is a simple example of a process to create, check, simulate and

release a Standard Xstep. We show here a material list with a safety

instruction. The procedure to create such a Xstep is listed below:

Create Folder

Create Standard XStep

Create XStep

Assign Destinations

Define Parameters

Assign Scope of Generation

Create Process Instructions

Check of XStep

Simulation of XStep

Release of Version

SAP AG 2006, RKT for <Manufacturing – Execution Steps>, <> 19

Procedure – Create Folder

SAP AG 2006, RKT for <Manufacturing – Execution Steps>, <> 20

Procedure – Create Standard XStep

SAP AG 2006, RKT for <Manufacturing – Execution Steps>, <> 21

Procedure – Create XStep

SAP AG 2006, RKT for <Manufacturing – Execution Steps>, <> 22

Procedure – Assign Destinations

SAP AG 2006, RKT for <Manufacturing – Execution Steps>, <> 23

Procedure – Define Parameters

SAP AG 2006, RKT for <Manufacturing – Execution Steps>, <> 24

Procedure – Assign Scope of Generation

SAP AG 2006, RKT for <Manufacturing – Execution Steps>, <> 25

Procedure – Create Process Instruction

SAP AG 2006, RKT for <Manufacturing – Execution Steps>, <> 26

Procedure – Create a Long Text

SAP AG 2006, RKT for <Manufacturing – Execution Steps>, <> 27

Procedure – Create a Long Text

SAP AG 2006, RKT for <Manufacturing – Execution Steps>, <> 28

Procedure – Check

SAP AG 2006, RKT for <Manufacturing – Execution Steps>, <> 29

Procedure – Simulate

SAP AG 2006, RKT for <Manufacturing – Execution Steps>, <> 30

Procedure – Simulate

SAP AG 2006, RKT for <Manufacturing – Execution Steps>, <> 31

Procedure – Release of Version

SAP AG 2006, RKT for <Manufacturing – Execution Steps>, <> 32

Prerequisites

Maintenance of XSteps in the Master Recipe :

To ensure that you can maintain XSteps in the master recipe, you

have to create a recipe profile when creating the recipe group.

The new recipe profiles

PI01_XS: Profile for the Process Industry XSteps

PI01XS2: Profile for Process Industry XSteps Optional

are provided as standard for the maintenance of XSteps.

To do this, access Customizing for the Master Recipe and choose

Settings for the Task List Type -> Define Profiles with Default

Values.

SAP AG 2006, RKT for <Manufacturing – Execution Steps>, <> 33

Prerequisites

Early Issue of Order Number :

As default, it is only possible to generate an XStep tree in a

process order once the order in question has been saved. You can

also set that an XStep tree is generated, even if it has not yet been

saved.

To do this, access Customizing for process management and

choose Execution Steps (XSteps) -> Set Early Issue of Order

Number.

SAP AG 2006, RKT for <Manufacturing – Execution Steps>, <> 34

Example Master Recipe

SAP AG 2006, RKT for <Manufacturing – Execution Steps>, <> 35

Example Master Recipe

SAP AG 2006, RKT for <Manufacturing – Execution Steps>, <> 36

Example Master Recipe – Simulation PI-Sheet

SAP AG 2006, RKT for <Manufacturing – Execution Steps>, <> 37

Example Master Recipe – Simulation PI-Sheet

SAP AG 2006, RKT for <Manufacturing – Execution Steps>, <> 38

Example Master Recipe – Simulation PI-Sheet

SAP AG 2006, RKT for <Manufacturing – Execution Steps>, <> 39

Agenda <Manufacturing – Execution Steps>

How to set up and use Execution Steps

Introduction

Summary

Solution : Manufacturing – Execution Steps

SAP AG 2006, RKT for <Manufacturing – Execution Steps>, <> 40

Features - Summary

Definition:

Execution steps are modules that you use to precisely

describe the execution process.

Usage for :

Creation of PI sheets

Communication between a process order and an external

control system; for example scales or a process control

system

Controlling the creation of confirmations or process

messages in the PI sheet: e.g. batch data, goods

movements, quality data

SAP AG 2006, RKT for <Manufacturing – Execution Steps>, <> 41

Business Value

Reduction of time for maintenance of process

instructions

Standard Xsteps can be used as a template or can be

referenced to a standard Xstep

Changes are made centrally in the XStep repository

Flexible Change Management (Versioning, Approval

Procedures, Classical Change Management)

Easy-to-use Editor

Test and Simulation Capabilities

Error reduction