s/4hana manufacturing for production engineering and ... · § production process planning is used...

PUBLIC

July, 2019

S/4HANA Manufacturing for Production Engineeringand Operations

Overview

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SAP S/4HANA Manufacturing for Production Engineering and OperationsApps and Capabilities

Production Operations

Production Order Management & ControlShop Floor Order

Complex Assembly Execution

Engineering ChangeIncorporation

Work Assignment& Work Queues

Perform Operationsand Activities

Tracking of Batchesand Serialized Parts

Action Log & Genealogy

• Operation/Activities• 3D Visuals• Work Instructions• Data Collection

Production Monitoring

Production Engineering

Manufacturing Change Management

BOMManagement

Production Process Planning

Assign newBOM versions

ChangeImpact

Analysis

ManufacturingChangeRecord

Visual EnterpriseManufacturing

Planner

Manage BOMsManageShop Floor Routings• Operation/Activities• 3D Visuals• Work Instructions• Data Collection• Qualification required• PRTs• Buyoffs• …

Manage QualificationRequirements

Manage StandardTexts

Manage BuyoffTemplates

BOM / RoutingVersion

Management• Qualifications required• PRTs• Buyoffs• …

Non-Conformance /Defect Handling

Model-Unit-Effectivity

Major Assemblies / Installation Kits


§ Production engineering bridges the gap between product engineering and productionoperations by converting the product design into production process design that is thebasis for production order management and shop floor execution.

§ Manufacturing change management orchestrates the end-to-end productionengineering process:– Assign New BOM Versions informs about new EBOMs or MBOMs versions and triggers

the production engineering process.– The Manufacturing Change Record is used to orchestrate the whole production

engineering process and keeps track of all changes made to manufacturing objectswhen incorporating a new EBOM version.

– The Change Impact Analysis identifies all objects that are impacted by a productengineering change.

– BOM and Routing Version Management controls the life cycle and usage of differentrevision levels.

§ The Visual Enterprise Manufacturing Planner is used to do the handover from theEBOM to the MBOM by converting the design-driven EBOM structure into amanufacturing, built-sequence driven MBOM structure.

§ Production process planning is used to create shop floor routings that include allinformation needed for production planning, production costing, and shop floorexecution:– Operations are used for planning and costing purposes as in classic PP-SFC.– Operation activities are used for shop floor execution and describe in detail how an

operation has to be performed: work instructions, data collection required, qualificationsneeded, PRTs, buyoff procedures, …

§ Production process planning includes a set of “supporting” features:– In the Manage Standard Texts app, you can maintain a library of reusable text elements

for efficient work instruction authoring.– Qualification requirements can be predefined for work centers and materials and are

inherited by related operations and activities.– Buyoff templates can be defined and used during routing maintenance.

Production Engineering Overview



BOMManagement


Assign newBOM versions

ChangeImpact

Analysis

ManufacturingChangeRecord


Planner

Manage BOMsManageShop Floor Routings• Operation/Activities• 3D Visuals• Work Instructions• Data Collection• Qualification required• PRTs• Buyoffs• …

Manage QualificationRequirements

Manage StandardTexts

Manage BuyoffTemplates

BOM / RoutingVersion

Management


Manufacturing EngineeringProcess Flow


Planner

Manageunassigned

BOMs

ManageRoutingsPLM

Change ImpactAnalysis

ProductionOrder ChangeManagement

Source-BOM

Change Record§ BOMs§ Routings§ Production Orders§ Purchase Orders

M-BOM

Routing ProductionVersion

ProductionOrder

ManageProduction

Version

ManageChange Records

§ The picture above describes the typical manufacturing engineering process in PEO.§ PEO receives new or changed BOMs from a PLM system and incorporates them into manufacturing master data and production orders (if required). The

source BOM can be an EBOM, preliminary MBOM, or shop floor MBOM.§ The change record is used to analyze, plan, and execute the changes required in a change cycle. It is an integrated environment that provides visibility and

access to all artifacts involved in the change cycle. Manufacturing engineers can plan and execute the changes to MBOMs, shop floor routings, productionorders and so on directly from the Change Record app.

§ The change impact analysis supports the manufacturing engineer to identify all manufacturing objects that are impacted by a change.


Manufacturing Change ManagementManage Unassigned EBOMs

§ Display new/modified engineering BOMswaiting for manufacturing handover as aworklist.

§ Assign EBOMs to relevant change records inthe context of the planning scope.

§ If the relevant planning scope and changerecord are already available, they aredisplayed and user can select them.– Also allows you to create them quickly with

most important attributes.§ Handle multiple versions of EBOMs.§ If changes are made directly to the MBOM and

not from the EBOM-MBOM, handover is notrequired. The app, Manage UnassignedMBOMs can be used to assign the MBOMs toa change record.


Manufacturing Change ManagementManage Unassigned EBOMs

§ The net change of an EBOM version displaysthe delta between the given version and itsprevious version. This gives you an idea of thescope of the change that has taken place inthe BOM.

§ The EBOM assignment need not be alwaysdone one by one. While performing theassignment for one EBOM, the systemautomatically identifies related EBOMs fromthe list which may be grouped together in thesame change record and allows the user toassign them together in one click.


Manufacturing Change ManagementManage Unassigned MBOMs

§ Sometimes the engineering changes maycome in the system directly as a new versionof the manufacturing BOM (not engineeringBOM), so no handover or EBOM to MBOM isrequired.

§ In such cases, it is the MBOMs and not theEBOMs that trigger the changes. Hence theMBOMs are assigned to a change record toget the change process started.

§ The Manage Unassigned MBOMs app workssimilarly to the Manage Unassigned EBOMsapp but, since the EBOM to MBOM handoveris not required, the planning scope is not used.– You can simply select the MBOMs and

assign them to an existing CR or create anew CR.


Manufacturing Change ManagementManufacturing Change Record

§ The Manage Unassigned EBOMs app createsand updates the change record with theEBOM and planning scope.

§ The change record defines the scope andphases of a change cycle.

§ It documents all changes by adding theimpacted and related objects to a changerecord.

§ Serves as an integrated entry point to accessall related objects and to trigger actions.


§ The primary purpose of a change record is tocontain references to all the objects that arerelevant for the change cycle.

§ The following objects are supported:– Master data: EBOM, MBOM, shop floor

routing, planning scope– Transactional data: Production order

§ Change items can be configured dependingon the change record type.

§ The context of the object in the change recordis indicated using the change relevance. Forexample ‘Create’, ‘Change’, ‘New Version’,‘Reference’ and so on.

§ The status network of the change record isconfigurable.

Manufacturing Change ManagementManufacturing Change Record - Items


§ You, as a manufacturing engineer, can use the changerecord as a single entry point where you can access allthe relevant objects for the change cycle.§ The change record enables you to navigate to the

corresponding apps to view or manipulate the objects.

Manufacturing Change ManagementManufacturing Change Record - Navigation

ChangeRecord

Manage BOM

ManageRouting

BOMHandover-

VEMP

Manage Order

ImpactAnalysis

…


§ Workflow can optionally be used to coordinatework among the different contributors andstakeholders of the change process.

§ Workflow can be defined using the ‘ProcessRoutes’ tab in the change record.

§ One or multiple sequential steps can becreated using the workflow. The steps definethe task details and also the agent propertythat is used to determine the recipient of thetask when the workflow runs.

§ You can also select the change record statusthat should be triggered when the step isinvoked. This enables the automatic transitionof the CR status via workflow step completion.

§ When workflow is running, the recipient isdetermined and the task is delivered to his/herinbox.

§ From the inbox, the agent can navigate to theManage Change Records App to view or makechanges to the change record. Also theavailable actions can be performed for thetask itself.

Manufacturing Change ManagementManufacturing Change Record – Workflow


Manufacturing Change ManagementChange Impact Analysis

§ The change impact analysis identifies allmanufacturing objects impacted by a BOM orrouting change. Objects considered areBOMs, shop floor routings, production orders,and directly related purchase orders(MTO/MTP/Direct Procurement) .

§ You can select one or more objects from thecontext of the change record as the triggerobject for the analysis.

§ The analysis result can be displayed in a list orin a network view mode. While the list is usefulto display all the impacted objects in aconsolidated manner, the network providesinsights on the relationships between theobjects.


Manufacturing Change ManagementChange Impact Analysis

§ Details of the impacted objects can bevisualized in the details area.§ Items, operations, and operation

activities affected by the change arehighlighted to visualize where the impactis.§ In case of model/unit effectivity, the

change impact analysis also identifiesthe units impacted by the change.§ Some quick actions can be done for the

impacted objects, for example, add tochange record, hold order, and so on.


§ A new mechanism of version-controlled material BOM is introduced wheredifferent change states of the BOM are represented using versions instead ofdate effectivity.§ The following table lists some important differences:

Manufacturing Change ManagementBOM Version Management

BOM Alt 1Version 1

BOM Alt 1Version 2

BOM Alt1Version 3

01/03/1701/01/17 01/05/17 01/07/17

<- Production Version (for Classical BOM) ->

01/01/17 01/07/17

BOM Alt 1

<- Production Version (for Version BOM) ->

Attributes Classical BOM Version BOM

Identification Identified by material, plant, usage, alternative. Identified by material, plant, usage, alternative +version.

Change states In case of BOM with history, the change statesare identified using ECNs.

No change states of BOM header or BOM item.Each version is a distinct instance of the BOM. Anychange in one BOM version shall not affect anotherversion.

Edit control The BOM alternative is always open for editing.ECNs are used to ensure the date effectivity ofthe change states.

Once released, a BOM version is frozen and doesnot allow any further changes. If changes arenecessary, you have to create a new version of theBOM alternative by copying the previous version.

BOMdetermination forproduction

Applicability of MBOM alternative for productionis determined by the production version butapplicable components are determined based onthe production date.

Applicability of MBOM version for production isdetermined by the production version. There is nofurther determination of BOM components as perproduction date.

Parametereffectivity

Supported Unitized parameter effectivity supported from 1809OP.

App access Accessible using legacy SAPGUI transaction aswell as new FIORI ‘Manage Bill of Material’ app.

Not accessible via legacy SAP GUI transactions.


§ The new shop floor routing is a version-controlled routing which enablesadditional capabilities for the operation activities in the operations This, inturn, enables an improved shop floor execution.§ Supports many new functions including operation activities, work instructions,

buyoffs, qualifications, and change alerts.§ The following table lists some important differences:

Manufacturing Change ManagementRouting Version Management

BOM V1 /Routing V1

BOM V1 /Routing V2

BOM V2 /Routing V3

01/03/1701/01/17 01/05/17 01/07/17

<- Production Version (for Classical BOM) ->

01/01/17 01/07/17

BOM Alt 1/Routing Group 1-Counter 1

<- Production Version (for Version BOM) ->(Determines a BOM Alternative and

Routing Group-Counter)

Attributes Classical Routing Shop Floor Routing

Identification Identified by group and group counter for task listtype N.

Identified by group and group counter + version.

Change states In case of routings with history, the changestates are identified using ECNs.

No change states of routing. Each version is adistinct instance of the routing. Any change in onerouting version shall not affect another version.

Edit control Routing is always open for editing. ECNs areused to ensure date effectivity of change states.

Once released, a routing version is frozen andcannot be changed. If changes are required, a newversion of the routing is created by copying theprevious version.

Routingdetermination forproduction

Applicability of routing for production isdetermined by production version but applicableoperations are determined based on productiondate.

Which routing version and BOM version are to beused for production is determined by the productionversion. There is no further determination of BOMcomponents and routing operations according to theproduction date.

Parametereffectivity

Supported Unitized parameter effectivity supported from 1809OP.

App access Accessible using legacy SAPGUI transaction. Can be accessed using the new Manage Shop FloorRoutings app and using the SAP GUI transaction(MSFR4).


§ The production version is the singlesource of supply for in-house productionwhich provides the exact BOM androuting alternative and versions to beused for production for a given date andorder quantity.§ The Manage Production Versions app

has been created and enhanced tosupport the version-controlled BOM andshop floor routing.– You can only assign a released BOM and

shop floor routing version to a productionversion.

Manufacturing Change ManagementManage Production Version

MBOM Management


MBOM ManagementVisual Enterprise Manufacturing Planner

§ Enables the handover of the engineeringstructure to the manufacturing structureassisted with an interactive 3D model.– Source panel contains the EBOM structure

and the visual (multi-level BOM).– Target panel contains the MBOM structure

and corresponding visual (multi-level BOM).– Working panel is the editing area where a

single-level BOM can be extracted from thetarget structure, and edited. The visual onlyshows the corresponding visual of thesingle-level BOM.

§ The components in the source panel aredisabled once they are fullyplanned/converted in the MBOM.§ VEMP reconciles the EBOM (source)

with the MBOM (target) to checkwhether any component is over or underassigned. If any discrepancy is found, itis highlighted in the correspondingnodes.


MBOM ManagementVisual Enterprise Manufacturing Planner

§ VEMP allows you to restructure theEBOMs in a different MBOM structureusing a quantity or parameter effectivitybased split or merge of EBOMcomponents into MBOMs.§ You can create synthetic MBOMs which

are only relevant for manufacturingusing VEMP while ensuring the designintent in the EBOM and the EBOMcomponent coverage.§ You can load the routing in the working

panel to allocate the components to therelevant operations.


Production Process PlanningShop Floor Routing – Entry Screen

§ The entry screen allows you to searchfor routings and to display, create, edit,and delete routings, or to set a routing toobsolete.§ You can adjust the layout and the search

criteria to the individual needs of the enduser.§ You can also create a new version or

copy a version to a new routing, andrelease a routing.§ Each version of the routing has a status.

Once you have released a routingversion, it cannot be changed.


Production Process PlanningShop Floor Routing - Header

§ You can assign a version profile in therouting header (controls successive/non-successive versions, for example).§ You can assign an MBOM to the routing

and either assign a manufacturingchange record (MCR) to the routing orcreate a new one.


Production Process PlanningShop Floor Routing – Operation Activities

§ Operation activities contain furtherdetailing options within an operation.§ There can be several operation activities

in an operation that are executed oneafter the other.§ Operation activities can belong to the

following segments: Setup, produce, orteardown.§ The operation activities are executed in

production not the operations.§ All aspects of the operation such as

component allocation, work instructions,inspection characteristics, PRTs,documents, buyoffs, qualifications, andaction handlers can be assigned tooperation activities.


Production Process PlanningShop Floor Routing – Simultaneous and Any-Order Groups

Any-Order Groups for OperationActivities§ Enable operation activities to be

executed in any sequence on the shopfloor.§ You define any-order groups during

routing maintenance. They are used togroup sets of operation activities that canbe completed in any sequence. Withineach group, however, you can alsodefine dependencies between activities.

Simultaneous Groups for OperationActivities§ Ensure that all operation activities in the

group can be executed simultaneouslyon the shop floor.


Production Process PlanningShop Floor Routing – BOM Management

§ One or more BOMs can be assignedto a routing (depending on routingprofile).§ You can assign MBOMs to the

routing that are not yet released.§ You can upgrade to a newer MBOM

version without loosing thecorresponding componentassignments.§ You can release an MBOM in the

routing application.


Production Process PlanningShop Floor Routing – Component Allocation

§ You assign components to operationactivities in the correspondingworkspace.§ The BOM items are displayed on the

left pane which shows the currentstate of component allocation.§ Components can be partially

allocated to different activities in anoperation.§ You can explicitly define the

assembly sequence of thecomponents. Enforcement duringshop floor execution can be turnedon or off.§ If available, a 3D visual can be

shown next to the MBOM item list. Aselected item in the MBOM list ishighlighted in the 3D image and viceversa.


Production Process PlanningShop Floor Routing – PRTs and Documents

§ You can assign PRTs(equipment and/or materials) tooperation activities in the PRTstab.

§ You can assign documents tooperation activities in theDocuments tab.


Production Process PlanningShop Floor Routing – Qualifications

§ You can assign one or morequalifications to operation activities.§ You can define the proficiency level

required for the operation activity.§ Only an operator with the required or

a higher qualification is allowed toperform the operation activity.


Production Process PlanningShop Floor Routing – Buyoff

§ The buyoff is a process to signoff on acomplex task by getting it reviewed byexperts.§ You can define a sequence of buyoffs

for an operation activity.– You can also copy buyoffs using the

buyoff template.§ A buyoff step consists of the description

and the team and/or function that canperform the step.§ Some buyoff steps may require

qualification checks too. These buyoffsteps can only be performed bypersonnel with required qualifications.


Production Process PlanningShop Floor Routing – Inspection Characteristics/Data Collection

§ You can define and assign inspectioncharacteristics to the operation activities.These readings can be utilized forquality management or for analyticalpurposes such as root cause analysis.§ You can use predefined master

inspection characteristics or createinspection characteristics specifically forthe routing.§ Characteristics can also be grouped

together to capture the readings in atable format. See the section for EmbeddedData Collection to see how these groupedinspection characteristics are represented intable format.§ You can copy appropriate characteristics

from other routings.§ The data for the inspection is collected

by operators using the “Perform Work”apps.


Production Process PlanningShop Floor Routing – Work Instructions

§ You can define rich text workinstructions for each operation activity.

§ The work instructions editor enables youto create content using rich text whichcan be authored directly in the editor.The editor supports features such asbackground color, foreground color, fontselection, font size selection,highlighting, and bulleting.

§ The instruction can also contain imagesbased on external source or using DMSattachment service.

§ Standard texts can also be used toenrich the work instruction content. Thestandard texts are rich text snippetswhich can be reused across severalwork instructions.

§ Work instructions and standard textscan be authored in different languages.During execution, they will be shown inthe logon language of the operator.


Production Process PlanningShop Floor Routing – Work instructions with embedded data collection

Interactive work instructions allow theproduction operators to record the datacollection required for component serialnumbers and batches as well as the readingsfor inspection characteristics:§ Clickable hyperlinks can be added in the

work instruction which, when selected,highlight the corresponding part in thecomponent list and the 3D model in thePerform Work app.

§ Serial number and batch collection forcomponents can be configured.

§ The inspection characteristics can also becollected multiple times in an easy-to-usetable format.


Production Process PlanningShop Floor Routing – Action Handler

§ The action handlers contain business logic, forexample, checks or determinations.

§ You can assign different action events tooperation activities.

§ If a production operator triggers the actionduring production order execution, the systemexecutes the checks or events associated withthe action handlers.


Production Process PlanningShop Floor Routing – Copy/Paste and Favorites

You can copy and paste operations andactivities, but also OA-related objects such aswork instructions, inspection characteristics,and PRTs within the same routing or to adifferent routing.

Favorites are organized in folder structures:

§ Private folders and their content can only bechanged and used by the user that createdthem.

§ Common folders can accessed and used byall users, but can only be maintained if youhave special authorization.


Different versions of a routing can becompared by turning the compare modeon:§ For each operation, operation activity,

and operation activity object (such asinspections characteristics, PRTs, …),you can see whether they are the samein both versions or not.

§ The system also shows the attributes ofboth versions for a given element (suchas standard values).

§ Work instructions are compared for allavailable languages and differences arehighlighted.

§ You can easily copy operations,operation activities, or operation activitydetails from one version to the other.

Production Process PlanningShop Floor Routing - Compare Routing Versions


§ A workflow can be defined formaintaining and reviewing ashop floor routing.

§ Individual users will receiveworkflow tasks in their inboxesbased on responsibilitydefinitions.

§ Manufacturing engineers canaccess and perform their workusing these tasks.

Production Process PlanningShop Floor Routing - Workflow


Production Process PlanningShop Floor Routing – Additional Capabilities

§ Production Version Creation andUpdates during Routing Release:Streamlines the process for engineers - noneed to navigate to another app.

§ Routing Check:You can execute this pre-check to make surethat the routing is ready to be released.

§ Extensibility:You can create customer-specific data forrouting header, operation and operationactivity.


Production operations is about initiating, preparing, executing, and documenting theactual end-to-end production process.Production Order Management & Control:§ The shop floor production order is an extended version of the PP production order:

– Operations are used for planning and costing as in classic PP-SFC.– Activities are used for shop floor execution and describe in detail how an operation

has to be performed: work instructions, data collection required, qualificationsneeded, PRTs, buyoff procedures, …

§ Production monitoring provides a comprehensive overview about the expected andactual status and progress of production orders and operations by automaticallydetecting exceptions, providing decision support, and immediate actions.

§ Engineering change incorporation allows you to update production orders with thelatest engineering changes.

Complex assembly execution is primarily designed for complex, low volume productionprocesses with high change frequency and focus on manual work – typical for complexassembly and engineer-to-order businesses:§ Work assignment and work queues orchestrate the actual execution of production

order operations and activities. Operators can access their tasks in work center workqueues or supervisors can explicitly distribute work to their team members by movingtasks to personal work queues.

§ The perform operations and activities apps support production operators in executingtheir tasks by guiding them through the production process with the help of interactivework instructions, 3D visual support, data collection with real-time valuations, and soon.

§ Defects handling manages non-conformances by placing holds on orders or parts,creating defects to be followed up by quality engineers and executing final usagedecisions.

§ Serialized parts are tracked and traced during the entire production process. Thegenealogy and action log collect all data and create a complete and detailed record ofhow a serialized part has been produced and how an order has been executed.

Production Operations Overview




Engineering ChangeIncorporation

Work Assignment& Work Queues

Perform Operationsand Activities

Defects Handling &Production Holds

Genealogy & Action Log

• Operation/Activities• 3D Visuals• Work Instructions• Data Collection• Qualifications required• PRTs• Buyoffs• …

Production Monitoring


Production OperationsProcess Flow

ManageProduction

HoldProductionHolds

Manage Production Orders /Production Operations

Defects ManageDefects

Buy Off ManageBuyoff

Genealogy

Production Order

Operations

Activities

Serial Numbers

PerformActivity

Manage WorkCenter Queue

Assign WorkPersonalWork Queue

My workqueue

PerformOperation

Action Log

ProductionConfirmation

§ The picture above describes a typical process flow of how production orders are executed.

§ Work is either triggered by work center queues or explicitly assigned to operators and accessed via personal work queues.

§ Holds, defects and buyoffs can be initiated from the worker UI (Perform Operation Activity). Holds can also be created from the monitoring apps.

§ All information gathered when performing activities plus all holds, defects, and buyoffs are documented in the genealogy and action log – on serial number granularity.

§ Production confirmations are automatically created and posted.

Production Order Management & Control



This list shows the main functions of ashop floor order and on which level ofgranularity they are provided:

§ The classic PP functionality on orderand operations level stays untouched.

§ Operations are mainly used forplanning, scheduling, and costing.

§ Activities are used to plan, execute,and document shop floor executionsteps.

§ When producing serialized parts,information is additionally tracked foreach individual serial number.

§ Some information is implicitlypropagated from the activity to theoperation level to ensure compatibilitywith existing PP functionality.

Function Order Operation Activity SerialNumber

BOM and routing explosion xDefine due date and priority xRelease x xScheduling xCosting xComponents required (x) xTool requirements (x) xWork instructions & 3D visuals xAttachments xQualification check xTrack production(for example, start, skip, pause, complete) x xBatches/serial numbers consumed (x) x xInspection characteristics (x) x xBuyoffs x xScrap (x) x xProduction confirmation (x)


Production Order Management & ControlProduction Monitoring

§ Monitors production processes either onproduction order or operation level to makedecisions in the most efficient manner.

§ Automatically detects exceptions/issues:- Holds- Delays- Missing components- Quantity deviations- Quality issues

§ Provides contextual information for rootcause analysis and decision support:

- Order schedule and history- Work center schedule and history- Material availability in plant and supply area- Operation activity details providing a complete

overview of the activity layer- Information on the inspection characteristics

collected and the results in the operationactivity details

§ Provides immediate actions:- Placing holds (for one or multiple production

orders simultaneously) and releasing holds- Manual order adjustments including order dates

and quantities- Order update with latest master data


Production Order Management & ControlEngineering Change Incorporation

§ Updating the shop floor order with the latestversion of the routing can be triggered fromthe monitoring app or directly from thechange impact analyses.

§ Supervisors can create holds on productionorders that are about to be updated toprevent shop floor people from startingproduction execution.

§ Once the update has been done,supervisors and shop floor operators arealerted about the changes that were made.


Complex Assembly ExecutionWork Assignment & Work Queues - Work Center Queue

§ Lists all operations to be performed ata given work center.

§ Supports the operator to pick the nextoperation to be worked on based on:

- Order and operation status- Priority- Scheduled start/end- Start feasibility- Issues (holds, missing components,

delays, …)

§ Additionally monitors all operationscurrently in process at the work center.The operator can see whichoperations can be processed withoutlimitations and which ones are blockedor can only be processed undercertain conditions. This provides theproduction operator with more supportwhen deciding which operation to workon next.


Complex Assembly ExecutionWork Assignment & Work Queues – Work Assignment and my Work Queue

Work Assignment:§ Select all unassigned operation activities or check

existing assignments.§ Assign one or more production operators to

individual operation activities to distribute the workload.

§ Filter operators' names by matching work centersand qualifications during an assignment.

§ View a number of current operator´s assignments.§ Add and edit target duration for an operation

activity during an assignment.§ Unassign operators from operation activities.

My Work Queue:§ View the work (operation activities) that has been

assigned to an individual operator.§ Sort, filter, and group the displayed operation

activities according to your needs.§ Start working on operation activities by directly

navigating to the Perform Operation Activity app.


Complex Assembly ExecutionPerform Operations and Activities § Supports the operator in performing and confirming

activities for orders or individual parts (serial numbers).

§ Validates proper execution.

§ Provides actions for reporting activity progress and status:- Start/Undo Start, Skip/Undo Skip, Pause/Undo Pause,

Complete/Undo Complete- Applying and releasing holds- Partial confirmations

§ Supports the operator in understanding the task:- Rich text work instruction- Interactive 3D model- Both linked to components list

§ Supports interactive data collection:- Serial/lot numbers consumed- Inspection characteristics

§ Ensures that the defined sequence of operation activities isconsidered during execution, considering any-order orparallel execution of operation activities. If multiple activitiesare available to start you can choose which one you want tostart with.

§ Provides buyoff timeline increasing visibility on buyoffhistory and upcoming steps.

§ Provides option to record defects during execution againstproduction order or individual serial numbers.

§ Provides the option of scrapping serialized parts.


Complex Assembly ExecutionPerform Operations and Activities – Interactive Work Instruction with Embedded Data Collection

§ In addition to the tabular data collection,the Perform Operation Activity appprovides a layout in which the productionoperator can collect component andinspection characteristics detailsinteractively while reading through thework instruction.

§ The Perform Operation Activity appautomatically switches to this layout ifpredefined for the selected operationactivity.

§ Supports embedded pictures, links tohighlight components in the 3D viewer,input fields for serial and batch numbers,as well as quantities.


Complex Assembly ExecutionPerform Operations and Activities – Labor Tracking

The labor tracking functionality can now beenabled for a work center that is laterassociated to an operation in the shop floorrouting, to:§ Track the time a production operator is logged on to

work on the operation activity at that work center.§ Provide a possibility for multiple operators to

collaborate at an OA that has been already startedby another operator (by laboring on to the sameserial number at the same OA).

The system starts tracking the time spent on theserialized product or an operation activity when aproduction operator starts or labors on.At the end of a shift, for example, one productionoperator labors off an operation activity while anotheroperator can still continue working on the operationactivity.The system automatically stops labor tracking for allproduction operators currently labored on to anoperation activity on completion of the operationactivity.


Complex Assembly ExecutionPerform Operations and Activities – Manage Buyoffs

§ Buyoffs verify the proper execution of anoperation activity. Experts of differentdomains have to check the work defined foran operation activity and approve a buyoff.

§ The Manage Buyoff app shows all openbuyoffs which a domain expert can approve(or reject).

§ Operation activities can have a buyoffprocedure with multiple steps. Every stephas to be approved by a different domainexpert. The buyoff app shows who alreadyapproved buyoffs for the same operationactivity.

§ Ad-hoc buyoff lines can be added duringbuyoff execution. That is, you can enhancethe buyoff cycle of an activity on the fly, ifnecessary.


§ Provides an option for production operatorsto record defects during the execution ofproduction activities.

§ Supports the recording of a defect with andwithout hold.

§ Displays the list of all recorded defects in thePerform Operation Activity app.

Complex Assembly ExecutionDefects Handing

§ Provides an option for the productionsupervisor to process defects.

§ Supports follow-up decisions:

- Use as-is

- Scrap

§ After the decision has been made, itbecomes available for the productionoperator in the defects list.

§ Prevents the usual completion of aserialized product if a scrap decision hasbeen made. The production operator isenforced to scrap.


Complex Assembly ExecutionAd hoc Rework

The unplanned rework feature enables theinsertion of an additional rework operationinto a production order based on a defect:§ For each plant, you can define one

generic rework routing with one reworkoperation and multiple operationactivities.

§ When a defect is recorded for aserialized product, the rework operationcan be added to the production order. Itis automatically placed after theoperation that is currently in process.

§ The defective part is automaticallymoved to the rework operation once thecurrent operation has been completed.

§ When executing a rework operation, theas-built list of components is shown. Ifdefective parts are to be replaced, youcan adjust the serial or batch numbers ofalready assembled parts.


Complex Assembly ExecutionProduction Holds

The hold functionality provides you with anoption to temporarily block production byplacing a hold on orders, materials,operations, work centers, or serial numbers.

§ When placing an object on hold, you can specify areason code and note.

§ If something is put on hold, production operatorscannot continue with their activities until the holdhas been released.

§ Holds are shown as an important exception on allsupervisor and operator UIs. Once the issue hasbeen solved, the hold can be released.

§ Enables you to monitor all production holds in theManage Production Holds app with a drill-downcapability to view the hold details.


Complex Assembly ExecutionGenealogy and Action Log

§ Complete as-built and where-usedinformation for individual parts.

§ Display of serial/batch numbers forconsumed components.

§ Drill in and drill out capabilities for operationactivity details.

§ Detailed log of activities and actionsperformed for an individual part:

- Date/Time- User- Activities started, completed, paused,

skipped- Buyoffs approved, rejected, canceled- Holds applied and released- Non-conformances raised (future

functionality)- Inspection characteristics (future

functionality)

§ Action log report with flexible querymechanism for detailed ad-hoc analysis.

Final Assembly / Installation Process• Major Assemblies & Installation Kits

• Unitized Effectivity (Model-Unit Effectivity)


A Major Assembly represents a large section of the product such as a wing or system module.

An Installation Kit is an organizational breakdown of the major assembly: Cutting the large BOM and the immense work that needs to bedone to produce the major assembly into portions that are easier to be handled.

Installation Kits have MBOMs and routings. Shop floor production orders are created for installation kits.

Major Assemblies do not have MBOMs and routings. They are produced by the sum of all their installation kits.

Installation ProcessMajor Assemblies & Installation Kits - Concept Overview

End Item

Major Assembly

Installation Kit

Assembly

Component

PS Project

Network

Network ActivityShop Floor Installation Order

Shop Floor Order

Shop Floor Order

PS

PEO

Major assemblies do not show up inproduction planning, but are represented bynetworks in the project system module (PS).

Installation kits are represented in both PSand PEO: In PS they are represented by theactivities of a major assembly’s network.Scheduling and sequence control is donebased on the network activities.

In addition, each activity also has a materialrequirement for the installation kit itrepresents. MRP reacts to them by creatingplanned orders for each installation kit that isconverted into shop floor installation ordersused for production execution.


Installation ProcessMajor Assemblies & Installation Kits – Features & Functions

§ Definition of material types to be used for majorassemblies and installation kits.

§ Installation kits can be defined in the VisualEnterprise Manufacturing Planner (VEMP).

§ Project Management Enhancement:- Consistent model/unit assignment within a project is

enforced.

- Serial numbers for major assemblies are automaticallycreated and linked to the major assembly networks.

- BOM version used for creating the installation kitrequirements of the major assembly are documentedand fixed.

- Defined installation kit precedence is enforced whenreleasing network activities.

- Consistency can be checked to ensure that majorassembly projects and networks are in sync withBOMs and other master data.

§ Shop Floor Order Enhancements- Installation orders can only be released if the related

network activity is already released.

- By completing an installation order, the relatednetwork activity will automatically be completed.

- Automatic goods issue posting for virtual installationkits materials after order completion.

- Installation order updates the genealogy of the majorassembly.


Installation ProcessUnitized Effectivity (Model-Unit Effectivity) - Concept Overview Parameter effectivity is a pre-existing functionality

to control the applicability of BOM items androuting operations in a BOM and routingrespectively, based on parameters such asmaterial, serial number, model, unit, and so on.Unitization (or model/unit pattern) is built on theparameter effectivity function to make use ofcertain semantic patterns and rules to ensure:§ An accurate incorporation of EBOMs into MBOMs

(version-controlled).

§ A compatible match between BOM components andthe routing operation activities. For example, assigna component that only applies to units 1 to 10 tooperation activities that are applicable for thoseunits.

The shop floor routing (version-controlled) hasbeen enhanced to support unitized parametereffectivity for operation activities too.The user interface for specifying parametereffectivity for the BOM and routing has beensimplified so that you can directly enter theeffectivity values without first having to generatean engineering change number (ECN).§ Matching ECN, if available, is found or a new ECN

is created for the effectivity automatically.

+ =

The landing gear for Aircraft Units 1 to50

• Drag Link required

• Wheel of Type A

• + other common parts

The landing gear for Aircraft Units 51 to100

• Drag Link not required

• Wheel of Type B


The Super-BOM for all aircraft units

• Drag Link: for Units 1 to 50 only

• Wheel of Type A: For Units 1 to 50

• Wheel of Type B: For Units 51 to 100


BOM Routing


Installation ProcessUnitized Effectivity (Model-Unit Effectivity) – in Visual Enterprise Manufacturing Planner

The version-controlled bill of material allows you to maintainparameter effectivity for BOM components.

The EBOM to MBOM handover is performed using VEMP.

In addition to the material and quantity of the BOM component,VEMP has also been enhanced to support the EBOM-MBOMreconciliation and incorporation using the parameter effectivity.§ The parameter effectivity is displayed in the tree table in a condensed

format and also in the side panel.

§ The effectivity of the BOM item is transferred from the EBOM to theMBOM on incorporation.

§ If needed, the effectivity of one or more MBOM component can bemodified.

§ An EBOM component can be split into multiple components within one ormultiple MBOMs based on quantity and parameter effectivity.

§ The quantity and effectivity of an EBOM component must match theoverall quantity and effectivity of all the corresponding MBOM splits. Anymismatch between the EBOM and MBOM item due to quantity and/oreffectivity is highlighted on both the EBOM and MBOM component.

§ A quick report for any EBOM component can show the exact nature of theinconsistency.

VEMP also allows BOM component assignment to routingoperations:§ The VEMP validates the applicability of the operation for the BOM

component. The effectivity of the operation must cover the effectivity ofthe BOM.

BOM


Installation ProcessUnitized Effectivity (Model-Unit Effectivity) – in Shop Floor Routing

The version-controlled shop floor routing supportsparameter effectivity.§ The overall parameter effectivity of the BOM is inherited

by the routing. This effectivity is displayed in the routingheader.

§ By default, the operations inherit the effectivity of therouting and the operation activity inherits it from theoperation. That is, you do not have to specify theeffectivity information for every aspect of the routingmanually which is intended to be same as the effectivity ofthe superior node.

§ If you require a custom effectivity, you can specify it for anoperation and/or operation activity. The user-definedeffectivity must still be such that it is covered by thesuperior node.– Effectivity can be reverted back to the inherited

effectivity.§ Operation activities may be split based on parameter

effectivity. This implicitly creates a group of activities whichhave mutually exclusive effectivity so that only one ofthem is selected for any given effectivity.


Installation ProcessUnitized Effectivity (Model-Unit Effectivity) – in Shop Floor Routing

The routing validates BOM component assignment tooperation activities to ensure that their effectivities matchand preempt the situation where components remainunassigned to an activity for any effectivity range.§ A BOM component can only be assigned to an activity of an

operation if the component effectivity is completely covered by theeffectivity of operation.– For example, a BOM component with the effectivity range 21 to

40 cannot be assigned to an operation with an effectivity range1 to 50. The BOM component effectivity must cover thecomplete operation effectivity.

§ A BOM component can only be assigned to an operation activity ifthe unallocated effectivity of the component covers the activityeffectivity.

§ A BOM component can be assigned to multiple activities of anoperation. The split is to be done in such a way that theaggregation of the quantity and effectivity of all splits is equal tothe quantity and effectivity of the BOM component.– For example a component with effectivity M1, 1-50; M2, 1-50,

70-100 can be assigned to an operation activity with theeffectivity M1, 1 to 50 and another activity with the effectivityM2, 1-50. The remaining effectivity of M2, 70-100 remainsunassigned.

– Another example: A BOM component with qty 5 and effectivityrange 1 to 10 can be split into three activities as follows: qty 2/range 1 to 5; qty 3/range 1 to 5; qty 5/range 6 to 10

§ The BOM component list in the component allocation workspacedisplays all the allocation splits and also the activities to whichthey are assigned. The remaining quantity and effectivity, ifavailable, is also displayed as an un-allocated split.

§ In case a 3D visual is relevant for the BOM, the geometricinstances are represented in the BOM component list tree.

Component List withAssignment Status

3D Visual for MBOM Assigned Componentsto Activity

Operation-ActivityStructure

Partially AssignedPartially Assigned

AssignedAssigned

UnassignedUnassigned


Installation ProcessUnitized Effectivity (Model-Unit Effectivity) – Filter in Routing Maintenance

When maintaining a routing, youcan set an effectivity filter:

§ The system only displays theelements (operations, activities,components) that are relevantfor the selected units.

§ All changes done within the filterare only relevant for the selectedunits.


Order Creation

Installation ProcessUnitized Effectivity (Model-Unit Effectivity) – in Shop Floor Execution

The order generation mechanism based onparameter effectivity works in same way as itworks for pre-existing functionality related toparameter effectivity.§ The effectivity parameters are specified in the project

network or sales order based on which the productionorders are created for specific effectivity.

§ The BOM and routing are filtered based on theeffectivity so that only the relevant components andoperation activities are applicable for the order.

The parameter effectivity is displayed in allproduction operation apps.

Order Detail

Perform Work

Contact information:

Stephan KohlhoffProduct Owner PEO, Manufacturing

[email protected]

+49 160 889 6921

Thank you.