SAP Manufacturing Integration and Intelligence at

Dunn-Edwards

Brij Mathur – IT Director

May 2011

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What We’ll Cover …

Introducing Dunn-Edwards

Assessing our goals, surveying our landscape

Understanding SAP MII

Leveraging SAP MII batch manufacturing templates

Improving quality management and plant maintenance using SAP MII

Integrating SAP and plant systems using SAP MII plant connectivity

Sharing lessons learned and seeing SAP MII at work

Wrap-up

Founded in 1925

Headquartered in Los Angeles, CA

Employee owned

Operates more than 100 retail outlets in Arizona, California, Nevada, New Mexico, and Texas

Serves both the professional painter and the consumer market

Slogan: “The #1 Choice of Painting Professionals”

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Dunn-Edwards Overview

Our Manufacturing Issues and Goals

Issues

■ Paper-based manual processes

■ Uncontrolled processes, e.g., tribal knowledge

■ Production bottlenecks

■ No real-time visibility

■ First Pass rates not at desired level

■ Limited production facilities

■ Inefficient processes

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Goals

■ Automated processes, no paper

■ System-controlled processes

■ Integrate end-to-end

■ Real real-time visibility

■ Improve First Pass percentage

■ Increase manufacturing production by significant margin

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Build a new state-of-the-art green field manufacturing facility

Located in Phoenix, AZ

Choose integration and visualization software

SAP MII (Manufacturing Integration & Intelligence)

SAP PCo (Plant Connectivity)

Resulting in:– Higher productivity for shop floor personnel

– Continuous improvement in processes and performance

– Faster time to value

– Quick development timeframe

Considering Our New Facility and Choosing the

Software

SAP

PCoOPC PcVue OPC

•Formulations •Transform &

Interface

• Recipe Management

• Sales and Operations Planning

• MRP

• Schedule & Process Orders

• Product Costing

• Transform &

Interface

• Simplify User

Data Entry

• Execute Process

Order

• Send Data Back

• Process Controllers

SCADA - PcVueControls – ISaGRAF

(Rockwell Automation)

Surveying Our System Landscape

Typical SAP MII Application Areas

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Using SAP Batch Manufacturing Templates

■ Collection of best practice templates for SAP MII

■ Prebuilt, plant and role-specific composites

■ Free of cost, downloadable from SAP Service Marketplace

■ Delivered by SAP AG from February 2010

■ Why did we use the SAP batch manufacturing templates?

■Reduced development

■Faster time to testing

■ Low risk

■Proven templates that work

■Free-of-charge

Work Instruction and Order List, SAP MII Batch

Manufacturing Template

Template: Date parameters are entered and executed to see schedule

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Using SAP MII for Quality Management

Combined two SAP Batch Manufacturing templates into oneResults Recording

■ Qualitative

■ Quantitative

Usage Decision■ Notify Chemist via email

Material adjustment

■ Generate Transfer Requirements (TRs) in SAP ECC

■ Post instructions to Shop Floor system

History of results recording

Send the batch back to Manufacturing

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Using SAP MII for Plant Maintenance

Simplified Web-based user interface for non-SAP users

■ Less complexity

■ Only necessary data is displayed to user

■ Only required data is entered by user

Integrated to SAP ECC on back end

■ Inherent, uncomplicated integration

■ Hidden from user

SAP MII logic decides what type of ticket and its importance before creating in SAP ECC

Maintenance Manager supervises all tickets in SAP ECC

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SAP Plant Connectivity

Plant Connectivity (PCo) is the name of SAP’s next-generation, high-performance manufacturing

plant connectivity software; enables real-time, event-driven integration between plant & enterprise

systems

Designed to:

■ Provide unsolicited real-time event notification capabilities from plant manufacturing systems to SAP

applications

■ Enable query execution capabilities against plant manufacturing systems (i.e., UDS-style queries, etc.)

■ Be a highly extensible plant connectivity infrastructure on which to build manufacturing applications

■ Provides the connectivity infrastructure enabling robust, high-performance integration between SAP and

Plant Systems

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Lessons Learned

Integrate the manufacturing engineering and IT teams

■ Held joint design sessions

Agreements and approvals required from all sides on requirements, design, testing, implementation,

cutover, and on-going support

Ensure integrated plant across all areas

■ Building construction

■ Software implementation

■ Systems integration

Infrastructure and network segmentation for process controls

Held weekly timeline and critical path meeting with architects, general contractor, key sub-contractors

■ Testing

Test Cycles

Cycle 1 Cycle 2 Cycle 3 Cycle 4

Business

Objective

SAP ERP functionality test SAP ERP with PcVue test Water Run Paint Run

Description Test PV5, SAP ECC & SAP MII

development & configuration

Integration Test PV5, SAP ECC, SAP MII & PcVue Integration Test PV5, SAP

ECC, SAP MII, PcVue &

IsaGraf

Production Run of PV5,

SAP ECC, SAP MII,

PcVue & ISaGRAF

Schematic

Comments In QA environment 1. In QA environment, testing 1 production line

2. Partial functionality in PcVue, from the

integrated testing perspective

1. In QA environment, testing

all 6 production lines

2. Full PcVue functionality

In Production

environment

Start Date 10/4/2010 10/18/2010 11/15/2010 1/10/2011

Product

Vision

ECC MII PcVue Product

Vision

ECC MII PcVue IsaGrafProduct

Vision

ECC MII

Lessons Learned (cont.)

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Your Turn!

How to contact me:

Brij Mathur

Brij.mathur@dunnedwards.com