Core Manufacturing

Arne MantheyASM Manufacturing03/2008

© SAP 2007 / Page 2

ERP

SFAC

Paradigm Change in the Definition of theManufacturing Landscape

MOM

SFAC

MES

SFAC

ERP

Separated Systems Principles

Plant MaintenanceEquipment QualificationMaintenance OrdersTime TicketsComponent -ConsumptionWork AssignmentTools

Plant MaintenanceEquipment QualificationMaintenance OrdersTime TicketsComponent -ConsumptionWork AssignmentTools

Production PlanningProduction Orders /Process Orders (S88)Operations / PhasesTime TicketsMaterial ConsumptionsPI Sheet / ElectronicWork Instructions

Production PlanningProduction Orders /Process Orders (S88)Operations / PhasesTime TicketsMaterial ConsumptionsPI Sheet / ElectronicWork Instructions

Warehouse Mgmt.Production SupplyTransportation Orders

Warehouse Mgmt.Production SupplyTransportation Orders

© SAP 2007 / Page 3

Quality Mgmt.Inspection TasksInspection LotsSample ManagementUsage DecisionTest Results -Recording

Quality Mgmt.Inspection TasksInspection LotsSample ManagementUsage DecisionTest Results -Recording

SAP ERP Touchpoint Processes withManufacturing

ERP

ERP

WMWMWMWM PMPMPMPM QMQMQMQM PP /PP /PPPP--PIPIPP /PP /

PPPP--PIPIAPOAPO

PP/DSPP/DSAPOAPO

PP/DSPP/DS

Human ResourcesQualification Records

Human ResourcesQualification Records

Materials Mgmt.Inventory ControlGoods MovementBatch InformationMaterial -ReservationsMaterial -CharacteristicsPurchasingTools

Materials Mgmt.Inventory ControlGoods MovementBatch InformationMaterial -ReservationsMaterial -CharacteristicsPurchasingTools

MMMMMMMMFIFI COCO HRHRHRHR

© SAP 2007 / Page 4

Manufacturing Levels and LandscapeUsing ERP Manufacturing only

FIFI COCO

ERP

/ SC

MER

P / S

CM

SFAC

SFAC

HRHRHRHR WMWMWMWM MMMMMMMM PMPMPMPM QMQMQMQM APOAPOPP/DSPP/DSAPOAPO

PP/DSPP/DS

DCS / PCSDCS / PCS

~1s

OPC

SAP ODA

DevicesDevices

PIPI--PCSPCS

Industrial Bus

PI Sheet /Electronic

Work Instructions

PP /PP /PPPP--PIPIPP /PP /

PPPP--PIPI

Aut

om. P

roce

ssM

essa

ges

…Weigh ScalesActors Meters

Synchronous Data Transfer Asynchronous Data Transfer

ProcessProcessMessagesMessages

ControlControlRecipesRecipes

FunctionFunctionCallCall

MO

MM

OM

~8h

SeparateManufacturingSystems(MES, LIMS, Maintenance)Visiprise / SAP ME,Werum, … )

SeparateManufacturingSystems(MES, LIMS, Maintenance)Visiprise / SAP ME,Werum, … )

Data HistorianData HistorianSCADA / HMISCADA / HMI

MII

© SAP 2007 / Page 5

Manufacturing Levels and LandscapePP / PP-PI

FIFI COCOERP

/ SC

MER

P / S

CM

SFAC

SFAC

HRHRHRHR WMWMWMWM MMMMMMMM PMPMPMPM QMQMQMQM APOAPOPP/DSPP/DSAPOAPO

PP/DSPP/DS

DCS / PCSDCS / PCS

OPC

SAP ODA

DevicesDevices

PIPI--PCSPCS

Industrial Bus

PI Sheet /Electronic

Work Instructions

PP /PP /PPPP--PIPIPP /PP /PPPP--PIPI

Aut

om. P

roce

ssM

essa

ges

…Weigh ScalesActors MetersSynchronous Data Transfer Asynchronous Data Transfer

ProcessProcessMessagesMessages

ControlControlRecipesRecipes

FunctionFunctionCallCall

MO

MM

OM Third Party

Systems(MES, LIMS, Maintenance)Visiprise, Werum, …

Third PartySystems(MES, LIMS, Maintenance)Visiprise, Werum, …

Data HistorianData HistorianSCADA / HMISCADA / HMI

Transaction DataMaster Data

XStepRepository

Routing / Recipe Production / Process Order

BOMXSteps

Header

Operations/ Phases

BOMXSteps

Header

Operations/ Phases

StandardXSteps

PP /PP /PPPP--PIPIPP /PP /PPPP--PIPI

© SAP 2007 / Page 6

PP / PP-PI:XSteps, Master and Transaction Data

Transaction DataMaster DataOrder

Work Centers/ Resources

Materials(MM)

XStepRepository

Routing / Recipe

+

+

+

BOMXSteps

Header

Operations/ Phases

+

++

+

+

BOMXSteps

Header

Operations/ Phases

+

+

+

+

+

Control Recipes

Electronic Work Instructions / PI Sheets

Documents(Cross)

Equipments(PM)

P P

Header with order information

Containers for Operations / Phases(can be collapsed)

Instruction containers for convenientstructuring

Long text elements are on the left side

Short text and input elements are on the rightside

Tables stretch over the whole widthRepeated data input (extendable with new lines)Grouped elements with similar structure(e.g. check lists, generated material lists, …)

Scrollable

Input history can be logged

Comments can be entered at any time

© SAP 2007 / Page 7

Features of the PI Sheet / Electronic WorkInstruction (I)

PI Sheet - ChangeProcess order: 000123456 Material Number 10001234 >>Change -> Display Save Complete Print Create Comment

Phase 0010

Goods receipt

Weighing

Preparation:• Enter production date• Enter tare weight of pallet• Enter average weight of pieces

Weighing• Put bin on the weigh scale• Get bin weight• Check result and confirm (OK?)

Sign the goods receipt

Production Date 08.06.2006

Tare weight of bins [kg] 1.000

Avg. piece weight [mg] 200.0

Signature

Total of pieces 21000

Output of text instructions

In- and output of valuesDefault values, value validation

Tables

Calculations

Function calls

OPC data access(e.g. read measurement from device)

Digital signature (simple, multiple)

Automatic generation of order-related object(e.g. documents, components,…)

Event-triggered execution of commands and functionsAutomatic execution of functions (e.g. immediate check of material status)Activation/deactivation of instructions based on conditions

Process messages(Activity reporting, material consumption/production,…)

© SAP 2007 / Page 8

Features of the PI Sheet / Electronic WorkInstruction (II)

Tablet weighing

XStep Life Cycle (I)SXS Repository Routing/Recipe Order

© SAP 2007 / Page 9

SXS Repository

XStep Section of Routing

XStep Section of Production Order

SXS with parameters

Generated elements(3 material componentsassigned to the order)

Parameter values related to a specific component

Automatic valuationof parameters

Routing-specific parameter values

XStep Section of Production Order

Electronic Work Instruction (EWI)

XStep Life Cycle (II):Order EWI/PI Sheet Process Message

© SAP 2007 / Page 10

Parameter values (Diameter Setup)

Line completed

PP_CONS Process Message

Material List in Production Order

Default value Deviation

Process messagebooks materialconsumption

© SAP 2007 / Page 11

Execution Steps – Summary

XSteps are easy to create and maintain. Much of the day-to-day work can bedone by functional departments. The IT department can concentrate on morecomplex areas.

The repeated use of standard building blocks (SXS) reduces the maintenanceeffort for the master data definition

‚One-stop shop‘ for the worker to access and provide all ERP-relatedinformation. No need to run multiple transactions.

Flexibility and speed by dynamic and event-triggered instructions

Control of the material and information flow between ERP and productionsystems (OPC)

Information and XStep examples are available on:BPX Community for Manufacturing

© SAP 2007 / Page 12

Thank you!