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Plant Centric : . A Strategy for Enterprise Integration. Richard M. Crossan, Jr. SAP America, Inc. Process Sector. OSI Software Users Group Meeting March 16, 1999. Topics. Plant Centric Strategy Why is it needed? Enterprise Integration Accurate portrayal of R/3 in manufacturing

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a strategy for enterprise integration

Plant Centric:

A Strategy for Enterprise Integration

Richard M. Crossan, Jr.SAP America, Inc.Process Sector

OSI Software Users Group Meeting

March 16, 1999

topics
Topics
  • Plant Centric Strategy
    • Why is it needed?
      • Enterprise Integration
      • Accurate portrayal of R/3 in manufacturing
    • What is the SAP Plant Centric Strategy?
  • R/3 in Manufacturing Operations
    • Components & Positioning
  • Partners & Interfaces
  • User-Centric Information

SAP America - Process Sector - 2

business drivers for integration
Business Drivers for Integration
  • Customer Responsiveness
  • Physical Plant & Equipment Responsiveness
  • Human Resources Responsiveness
  • Global Market Responsiveness
  • Teaming as a Core Competency
  • Responsive Practices & Culture

Next-Generation Manufacturing Project

SAP America - Process Sector - 3

three reasons to integrate
Three Reasons to Integrate:
  • Improve performance of the supply chain:
    • enterprise wide business processes
    • accurate planning and scheduling
    • responsive execution
    • status of the order
  • Improve performance of the production plant:
    • visibility of enterprise business processes
  • Combined platform for agility:
    • plant - supply chain collaboration
    • New Product Development, Customer service...

SAP America - Process Sector - 4

interdependencies highlight key roles

Business Drivers

Supply Chain link

Production link

Highest quality

(Brand image)

Customer order

specification.

Reduced variability

Delivered product

cost

Lowest cost

Eliminated waste

Optimized supply

chain costs

Optimized

production costs

Highest margins

Increased “ agility ”

(Product availability)

Delivery to schedule

Produce to schedule

Effective New Product

Development

Time to first packaged

batch in control

Time to peak sales

Fulfilled order / demand

satisfied customers

Expanded customer base

Reduced costs of

compliance

Conformance to

cGMP,HACCP ,SOP

Regulatory compliance

Sustainable Competitive

Advantages

Organizational

effectiveness

Interdependencies Highlight Key Roles!

Produce to specification

Coordination, optimization

& synchronization

SAP America - Process Sector - 5

why is an sap plant centric strategy needed
Why is an SAP Plant Centric Strategy needed?
  • To address the changing demands on plant systems:

“...manufacturing must shift from the center of the enterprise to become a node in the network of activities that serves the end customer. “ Gartner Group

  • To address the integration demands within the business due to changing role of manufacturing
  • To address incorrect perceptions of R/3 capabilities in manufacturing
  • To clarify R/3 functions with respect to Manufacturing Execution System functions
  • To help customers extend the benefits of R/3 into manufacturing

SAP America - Process Sector - 6

misperceptions of r 3 in manufacturing
Misperceptions of R/3 in Manufacturing
  • R/3: More than Financials, Order Entry & Human Resources
  • No need to ‘rip out’ your PLCs, DCSs, SCADAs or LIMSs
  • Clarification of “Realtime”
    • Minutes & Seconds vs. Sub-second
  • Clarification of “Execution”
    • Product vs. Processes
  • Clarification of “Processes”
    • Business Workflow vs. Manufacturing

SAP America - Process Sector - 8

r 3 and plant operations
R/3 and Plant Operations
  • R/3 provides a much of the infrastructure needed for the flow of the information between business operations and plant systems
  • However:
    • SAP Partners - their systems & skills - play a critical role in the pursuit of integration
  • SAP customers considering the roll-out of R/3 into plants must ensure that the information models created for their business processes can be effectively utilized at the plant level.

SAP America - Process Sector - 9

what is sap plant centric an sap strategy for business to manufacturing integration
What is SAP Plant Centric?An SAP strategy for business to manufacturing integration
  • Elements:
      • Partner Initiatives & Alliances
      • Consulting Services
      • Solution Offerings
      • Product Development Enhancements
  • Plant Centric is intended to provide focus, not to create new mechanisms

SAP America - Process Sector - 10

plant centric and sap programs
Plant Centric and SAP programs
  • Plant Centric is intended to provide focus, not to create new mechanisms
  • Existing partner programs will be utilized
  • SAP Process Industry organization will focus on partners which pursue Plant Centric projects
  • Activities will be consistent with SAP vertical industry directions

SAP America - Process Sector - 15

plant centric responsibilities
Plant Centric Responsibilities
  • SAP: Improve the level of manufacturing-oriented information about R/3
  • Customers: Include Enterprise-wide manufacturing automation strategies early in the R/3 implementation cycle
  • Partners:
    • Global & National Consultants:
      • R/3 + manufacturing systems skills
    • Plant Systems Providers:
      • Interfaces, consultant & integrator relationships
    • Plant Systems Integrators:
      • Consultant relationships

SAP America - Process Sector - 17

delivery of mes functions

ERP

ERP

MES

MES

Control

Control

Delivery of MES Functions

Original Model

Delivery of Functions

SAP America - Process Sector - 19

r 3 mes
R/3 & MES
  • Does SAP have an MES component?

“SAP provides many of the MES level functions throughout the components of R/3. Some of the MES functions within the MESA model must be provided in conjunction with SAP partners. Only a discussion on the specific functions of interest can provide an answer to the question.”

SAP America - Process Sector - 20

r 3 coverage within mesa model

R/3

R/3 Coverage within MESA Model

MES: Manufacturing Execution Systems

SSM: Sales & Service Management

SCM: Supply Chain Management

ERP: Enterprise Resource Planning

P/PE: Product and Process Engineering

Controls: PLC, DCS, line & machine control

MESA White Paper #6

SAP America - Process Sector - 21

critical nature of partners
“Critical Nature of Partners”
  • Strong Customer Relationships at Plants
      • Long term involvement
      • Regional resources
      • Customer Operations knowledge
  • Unique skills differentiated by industry & application areas
  • Partners are First Point of Contact for plants

“Plants don’t call SAP”

SAP America - Process Sector - 24

partner programs interfaces
Partner Programs & Interfaces
  • CSP: Complementary Software Program
    • Certified
    • ISV: Independent Software Vendor
  • Global Implementation Partner
  • National Implementation Partner
  • Interfaces
    • BAPI: Business Application Programming Interface
    • Standard Interfaces

SAP America - Process Sector - 25

csp eco system
CSP “Eco-System”

CSP

Members

Development

Partners

BAPI Certified

BAPI Validated

BAPI

Certification

in process

BAPI

Validation

in process

Qualified

ISVs

CSP Participants

CSP

Applicants

SAP America - Process Sector - 26

plant centric components
Plant Centric Components
  • Production Planning (PP)
  • Production Planning - Process Industries (PP-PI)
  • Process Flow Scheduler (PFS)
  • Environmental Health & Safety(EHS)
  • Materials Management(MM)
  • Quality Management(QM)
  • Plant Maintenance(PM)
  • Warehouse Management(WM)
  • Controlling(CO)
  • Human Resources(HR)

SAP America - Process Sector - 27

plant centric interfaces
Plant Centric Interfaces
  • PI- PCS SCADA & Process Control Systems Weighing Systems
  • QM- IDI Laboratory Management Systems
  • PP- DMS Document Management
  • MM- MOB Data Collection
  • PP- POI Process Optimization Interface
  • PP- PDC Plant Data Collection
  • PM - PCS Plant Equipment
  • PP- CAD Computer Aided Design
  • WM- LSR Warehouse Control Units
  • BAPI Business API

SAP America - Process Sector - 29

csp certified
CSP Certified
  • PI-PCS OSI Software - Hewlett-Packard - Digital Equipment - EnvisionIt - Foxboro - AspenTech - Hartmann & Braun - Siemens AG - Yokagowa - IBM - Mettler-Toledo - Elsag Bailey - Sequencia
  • QM- IDILab Systems - Labware - HP - Beckman - Perkin Elmer - ...
  • PP-DMS Documentum - Siemens AG - Interleaf
  • MM-MOBIntermec - Siemens - Teklogix - EPIC - Software Consulting Partners - CIM Vision - Norand - ...
  • OTHERS...

SAP America - Process Sector - 30

independent software vendors
Independent Software Vendors
  • Intellution (Emerson)
  • Wonderware (Siebe)
  • Rockwell Automation
  • POMS
  • Gensym
  • ...Others
  • ABB - Elsag-Bailey
  • Siebe: Simulation Sciences / Biles & Associates
  • Fisher-Rosemount
  • Moore Products
  • Honeywell
  • GE Fanuc

SAP America - Process Sector - 31

implementation partners
Implementation Partners
  • Plant Specific
          • Honeywell
          • Foxboro
  • Consulting Partners(Manufacturing focus)

Deloitte Consulting / ICSCap Gemini

KPMG Ernst & Young

Origin IBM

Price Waterhouse / Coopers Hatch Associates

IDS Prof. Scheer Andersen Consulting

Osprey Systems Others …

  • SAP Consulting
  • Local Systems Integrators

SAP America - Process Sector - 32

business object with bapis and associated function modules
Business Object, with BAPIs and Associated Function Modules

RFC Library

COM/DCOM, CORBA, Java, ActiveX, ...

SAP America - Process Sector - 34

plant implementation puzzle

Customer

“Plant Implementation Puzzle”

Enterprise SAP Implementation

Global Implementation Partners

Corporate

Driven

Manufacturing

Implementation

Partners

SAP

Plant

Driven

Local

Integrators

Plant

systems

Plant Centric helps with this puzzle !

SAP America - Process Sector - 35

technical view components

Function

Function

Function

Function

Function

Function

Function

Function

Function

Function

Function

Function

Function

Function

Function

Function

Function

Function

Function

Function

Function

Function

Function

Function

Function

Function

Function

Function

Function

Function

Function

Function

Function

Function

Function

Function

Function

Function

Function

Function

Function

Function

Technical View: Components

APO

BW

PM

PP

MM

PP-PI

QM

SAP America - Process Sector - 37

user centric view scenarios

Function

Function

Function

Function

Function

Function

User-Centric View: Scenarios

MM

PM

PP-PI

QM

Function

Function

Function

Function

Function

Function

Function

Function

Function

Function

Function

Function

Function

Function

Function

Function

Function

Function

Process Operator Cockpit

Function

Function

Function

User Scenario

Function

Function

SAP America - Process Sector - 38

new model of manufacturing business processes

(Plan)

(Source)

(Deliver)

Coordinate

Ready

Analyze

Execute

Process

New Model of Manufacturing Business Processes

R E P A C

Model

Plant-Centric:

to make the manufacturing plant

a responsive part of the supply chain!

SAP America - Process Sector - 39

r e p a c ready coverage

Ready

R E P A C: Ready Coverage
  • Create, enhance, or make ready production processes
  • Transforms products designs of specifications to introduce new product to plant

Coordinate

Analyze

Execute

Process

SAP America - Process Sector - 40

r e p a c execute coverage
R E P A C: „Execute“ Coverage
  • Executes orders or production schedules for products
  • Sets up PROCESS to make a specific product

Coordinate

Ready

Analyze

Execute

Process

SAP America - Process Sector - 41

r e p a c process coverage
R E P A C: „Process“ Coverage
  • Processes the plant uses to physically produce many products
  • Automate and control of the process

Coordinate

Ready

Analyze

Execute

Process

SAP America - Process Sector - 42

r e p a c analyze coverage
R E P A C: „Analyze“ Coverage
  • Production performance, product capability, regulatory compliance
  • Combines data from multiple components (routine & add hoc)
  • Assemble data for ERP, SCM, customers and suppliers

Coordinate

Ready

Analyze

Execute

Process

SAP America - Process Sector - 43

r e p a c coordinate coverage
R E P A C: „Coordinate“ Coverage
  • Coordinate plant operations with enterprise and supply chain
  • Optimize plant activities to meet production requirements (demand)

Coordinate

Ready

Analyze

Execute

Process

SAP America - Process Sector - 44

plant centric views
Plant Centric Views
  • User/Audience Focus
  • Industry Independence
  • Augment Existing “Maps”
  • Delivery Vehicle for Plant Centric Information
  • Clarity with respect to USE instead of FUNCTION
  • Information from development, IBU, Industry Sectors and partners

Plant Centric Views

SAP America - Process Sector - 45

plant centric activities
Plant Centric Activities
  • IMS Expo: Executive Committee & Exhibitor
  • ISA SP95: Enterprise Integration Standard
  • OPC: OLE for Process Control
  • Process Industry SAP Users Group (PISUG) - Plant Centric Task Group
  • Interkama 1999
  • S88 - General & Site Recipe Definition
  • Plant Centric Conference - Frankfurt
    • March 29-30, 1999

SAP America - Process Sector - 46

international manufacturing software ims expo
International Manufacturing Software (IMS) Expo
  • Orlando, Florida - April 26-29, 1999
  • Enterprise Integration Focus
  • Manufacturing level software
  • Cross industry
  • IT & Manufacturing audience
  • Solutions & Partnership emphasis
  • WWW.IMS-EXPO.ORG

SAP America - Process Sector - 47

summary
Summary
  • The Plant Centric strategy assists with the issues of business to plant operations integration.
  • R/3 provides the information backbone for enterprise integration
  • R/3 has the broad capabilities to manage manufacturing businesses
  • R/3 interfaces, partner products and services complete the “puzzle” down to the plant floor.

SAP America - Process Sector - 48

slide40

for the Plant

PLANT CENTRIC

“... intended to transcend the debates on product capabilities and focus on the responsibilities for executing the solution.”

SAP America - Process Sector - 49