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Performix Inc: Implementing MES in SAP Landscape. Implementing MES in SAP Landscape. Sham Afzalpurkar CEO, Performix Inc. September 26 th , 2006. Introduction. Sham Afzalpurkar, CEO Performix Inc About Performix A Manufacturing Execution Systems company Developing xApps in MES space

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implementing mes in sap landscape

Implementing MES in SAP Landscape

Sham Afzalpurkar

CEO, Performix Inc.

September 26th, 2006

introduction
Introduction
  • Sham Afzalpurkar, CEO Performix Inc
  • About Performix
    • A Manufacturing Execution Systems company
    • Developing xApps in MES space
    • Significant Supply Chain, Manufacturing Execution &Track/Trace experience
    • Focus on Pharmaceuticals, Process Industries and Hi Tech
    • Offices in Houston, Texas with development teams in India
agenda
Agenda
  • Overview of MES
  • Justifying MES
  • Developing MES Strategy
  • MES Architecture
  • Integration Strategy
  • Implementation Plan
  • Lessons Learned
why mes
Why MES?
  • In the last decade, ERP and SCM have NOT delivered the expected returns
  • Focus on deploying MES solution to give visibility and flexibility and effectively manage supply chain
  • Competition has forced quality products at lower cost
  • Integration of ERP and MES has been a challenge
  • Standards such ISA 95 provide the potential to simplify deployment
what is manufacturing execution system
What is Manufacturing Execution System?
  • Co-ordinate functions on the shop floor to optimize the plant activities
  • Manufacturing Execution System provides effective integration between production processes and enterprise business systems.
  • Layer of communication between business and control systems

ERP

MES

SHOP FOOR AUTOMATION

components of mes
Components of MES
  • Core
    • Material and Production Tracking
    • Material Handling and Production Procedures
    • Resource management and allocation
    • Production Dispatching
    • Data Collection
  • Extensions
    • Compliance
    • Quality Assurance
    • Performance Analysis
    • Detail Scheduling
    • Document Management
    • Labor Management
what is isa 95
What is ISA 95?
  • Instrumentation, Systems, and Automation Society (ISA) Standard
  • Standard that defines how to link Enterprise and Controls systems using a Manufacturing Execution Systems (MES) layer. This standard describes:
    • The MES Functionality
    • The Data base schema at the MES Level
    • The Messages between the Enterprise system and MES
what is b2mml
What is B2MML?
  • The World Batch Forum (WBF) has published XML schemas based on the S95 Model - B2MML (Business to Manufacturing Markup “Hypertext” Language)
  • B2MML-V0201-Common.xls
  • B2MML-V0201-Personnel.xls
  • B2MML-V0201-Equipment.xls
  • B2MML-V0201-Material.xls
  • B2MML-V0201-Maintenance.xls
  • B2MML-V0201-ProcessSegment.xls
  • B2MML-V0201-ProductionDefinition.xls
  • B2MML-V0201-ProductionCapability.xls
  • B2MML-V0201-ProducitonPerformance.xls
  • B2MML-V0201-ProductionSchedule.xls
agenda11
Agenda
  • Overview of MES
  • Justifying MES
  • Developing MES Strategy
  • MES Architecture
  • Integration Strategy
  • Implementation Plan
  • Lessons Learned
justifying mes business drivers
Justifying MES – Business Drivers
  • Visibility of data globally
  • Standard processes
    • Enable benchmarking and best practices
  • Consistent Documentation
  • Resource Utilization
  • Accurate and consistent KPI
  • Seamless Integration
justifying mes benefits
Justifying MES - Benefits
  • Increases Operational Excellence
  • Lower Operating Costs
  • Asset Management
  • Reduced Total Cost of Ownership
agenda14
Agenda
  • Overview of MES
  • Justifying MES
  • Developing MES Strategy
  • MES Architecture
  • Integration Strategy
  • Implementation Plan
  • Lessons Learned
manufacturing assessment planning
Manufacturing Assessment & Planning
  • What are the business drivers?
  • What are the organizational and process related issues?
  • What should be done first – aligning manufacturing strategy with business strategy
business functions s95
Business Functions (S95)

Enterprise Performance Reporting

Level 4

Business

Planning &

Logistics

Demand

Planning

Supply Chain Planning

Cost Accounting

Human Resource

Management

Sales &

Distribution

Material

Management

Production

Planning

Warehouse

Management

Maintenance

Management

Detail Scheduling

Process

Optimization

Recipe

Management

Performance

Management

Process

Analysis

Level 3

Manufacturing

Operations

Resource

Management

Production

Execution

WIP Material

Management

Production

History

Quality

Management

Real-Time

Execution

Real-Time

SPC

Level 2

Plant Floor

Control

Real-Time

Control

Real-Time

Monitoring

simple discrete

ERP

Enterprise Performance Reporting

Demand

Planning

Supply Chain Planning

Cost Accounting

Human Resource

Management

Sales &

Distribution

Material

Management

Production

Planning

Warehouse

Management

Maintenance

Management

Detail Scheduling

Performance

Management

Process

Analysis

Resource

Management

Production

Execution

WIP Material

Management

Production

History

Quality

Management

Some PLCs

Machines & Work Centers

Fixed Routes, No Lot Splitting

Only Ingredients Changes

Real-Time

Execution

Real-Time

SPC

Real-Time

Control

Real-Time

Monitoring

Simple Discrete
complex discrete

ERP

Enterprise Performance Reporting

Demand

Planning

Supply Chain Planning

Cost Accounting

Human Resource

Management

Sales &

Distribution

Material

Management

Production

Planning

Warehouse

Management

Maintenance

Management

Detail Scheduling

Process

Analysis

MES Thousands of parts, complex procedures, many products

Resource

Management

Production

Execution

WIP Material

Management

Production

History

Quality

Management

Some PLCs

Machines & Work Centers

Production Lines

Real-Time

Execution

Real-Time

SPC

Real-Time

Control

Real-Time

Monitoring

Aerospace and Automotive

Complex Discrete
slide19

ERP

Enterprise Performance Reporting

Demand

Planning

Supply Chain Planning

Cost Accounting

Human Resource

Management

Sales &

Distribution

Material

Management

Production

Planning

Warehouse

Management

Maintenance

Management

many shared resources, complex routing, many products

MES thousands of parts, complex procedures

Detail Scheduling

Process

Optimization

Recipe

Management

Performance

Management

Process

Analysis

Resource

Management

Production

Execution

WIP Material

Management

Production

History

Quality

Management

Some PLCs

Machines & Work Centers

Production Lines

Real-Time

Execution

Real-Time

SPC

Real-Time

Control

Real-Time

Monitoring

Semiconductor

slide20

Pharmaceuticals & Specialty Chemicals

ERP

Enterprise Performance Reporting

Demand

Planning

Supply Chain Planning

Cost Accounting

Human Resource

Management

Sales &

Distribution

Material

Management

Production

Planning

Warehouse

Management

Maintenance

Management

many shared resources, large recipes, many products

MES compliance, complex procedures

Detail Scheduling

Process

Optimization

Recipe

Management

Performance

Management

Process

Analysis

Resource

Management

Production

Execution

WIP Material

Management

Production

History

Quality

Management

SCADA / PCS

Equipment Trains

Flexible Connections

Real-Time

Execution

Real-Time

SPC

Real-Time

Control

Real-Time

Monitoring

slide21

Oil & Gas and Bulk Chemicals

ERP

Enterprise Performance Reporting

Demand

Planning

Supply Chain Planning

Cost Accounting

Human Resource

Management

Sales &

Distribution

Material

Management

Production

Planning

Warehouse

Management

Maintenance

Management

SCADA / PCS

Equipment Trains

Fixed Connections

Large number of control variables, real-time optimization

Process

Optimization

Performance

Management

Process

Analysis

Production

History

Quality

Management

Real-Time

Execution

Real-Time

SPC

Real-Time

Control

Real-Time

Monitoring

mes functionality
MES Functionality
  • Dispatching and Production
  • Resource Allocation
  • Quality Management
  • Data Collection
  • Process Management
  • Production Tracking and Genealogy
  • Document Control
  • Performance Analysis
  • Operational Detail Scheduling
dispatching production
Dispatching Production
  • Manages the flow of production in the form of jobs, orders, batches, lots and work orders by dispatching production to specific equipment and personnel. Includes information that is presented in the sequence in which the work needs to be done.
resource allocation status
Resource Allocation & Status
  • Manage the resources directly associated with control and manufacturing.
data collection acquisition
Data Collection & Acquisition

Obtains operational production and parametric data associated with production equipment and processes. Provides real-time statuses of production equipment and processes.

quality management
Quality Management
  • Provides real-time measurements collected form manufacturing to assure proper product quality control and to identify problems requiring attention. Includes SPC / SQC tracking and management of offline inspection operations

.

process management
Process Management
  • Monitors production and either automatically corrects or provides decision support to operators for correcting and improving in-process functions. It may include alarm management to handle process deviations.
production tracking genealogy
Production Tracking & Genealogy
  • Provides status of production and disposition of work. Status information may include personnel, materials used, current production conditions. Includes recording of production information to allow forward and backward traceability.
performance analysis
Performance Analysis
  • Provides real-time reporting of actual manufacturing operations results along with comparisons to past history and expected results. Performance results include resource utilization, resource availability, cycle time, conformance to schedule and standards. May include SPC / SQC analysis
operations detailed scheduling
Operations & Detailed Scheduling
  • Provides sequencing based on priorities, attributes, characteristics and production rules. It is finite and it recognizes alternative and overlapping operations to calculate timing of equipment loading
document control
Document Control
  • Control records and forms that must be maintained with the production unit. Includes work instructions, recipes, drawings, standard operating procedures (SOP), batch records, shift to shift communication. It sends instructions down to operations and device controls
labor management
Labor Management

Provides status of personnel. Includes time and attendance, certification tracking, as well as preparation work as basis for activity–based costing. May interact with resource allocation for optimal assignments.

maintenance management
Maintenance Management
  • Functionality for maintaining equipment and tools. Ensures equipment and tools availability for manufacturing. May also include scheduling for periodic or preventive maintenance. Maintains history of past events to aid in diagnosing problems.
agenda34
Agenda
  • Overview of MES
  • Justifying MES
  • Developing MES Strategy
  • MES Architecture
  • Integration Strategy
  • Implementation Plan
  • Lessons Learned
slide35

SAP MES Architecture

APO

Demand Planning

SNP

PPDS

Global

ATP

SAP R/3

BW

Plant Maintenance

Materials

Management

Production Planning

Quality

Management

Human Resources

xMII

Integration

Intelligence Dashboard

S95

Master & Transaction Data

xApps/Composite Apps

MES

OPC

LIMS

Historian

PAT

SCADA

Devices

Doc Mgmt

agenda36
Agenda
  • Overview of MES
  • Justifying MES
  • Developing MES Strategy
  • MES Architecture
  • Integration Strategy
  • Implementation Plan
  • Lessons Learned
sap mes integration options
SAP MES Integration Options
  • Use SAP xMII – Preferred
  • Build your own XI integration
slide38

Enterprise

SAP NETWEAVER

SAP Manufacturing

(mySAP ERP)

Manufacturing Intelligence Dashboards

SAP BI

Other SAP Bus. Solu tions

XI

SAP xMII

Manufacturing Intelligence

Manufacturing Integration

Plant Floor

SAP MES Integration Using xMII

  • SAP xMII enables real-time transactional integration between plant floor and enterprise (SAP ERP) systems out-of-the box thru:
  • Universal Connectivityto the data, functionality and processes of existing plant floor systems and SAP
  • Advanced composite application capabilitiesfor creating automated events, KPIs and alerts, and new manufacturing business processes
  • Synchronization of SAP ERP with real-time Plant Floor Systems and Processesusing proprietary and standards-compliant messages and workflows
  • Data Services that provide a foundation for Manufacturing Synchronization and Intelligence
mes integration with sap using xmii

Shopfloor Application – ANSI/ISA-95 Compliance

B2MML Msg

SAP R/3, SCM, BW…

MES Integration with SAP – Using xMII

PEOPLE

SAP Enterprise Portal

INFORMATION

SAP xMII

Integration

Use xMII Integration capabilities if S95 Non Compliant

= SAP

= 3rd Party Application

agenda40
Agenda
  • Overview of MES
  • Justifying MES
  • Developing MES Strategy
  • MES Architecture
  • Integration Strategy
  • Implementation Plan
  • Lessons Learned
mes deployment strategy
MES Deployment Strategy
  • Understand the problem you are trying to solve
    • The business drivers
  • How you deploy has impact on cost and scope
  • Integration with Process Control and other applications
  • Change in the business processes
  • Facility readiness
slide42

Analyze manufacturing processes and develop MES requirements

Map requirements with SAP Functionality.

Assessment

Map

MES Requirements

Detail plan for pilot and rollout

Design

MES Architecture

Identify gaps

Develop Deployment

Plan

Develop global processes, Integration touch points

Pilot

Roll Out

Review Pilot results

Start

Ramp-up

why pilot
Why Pilot?
  • Enhance understanding of MES
  • Determine how well current requirements fit into an MES
  • Validate the Integration strategy
scope of pilot
Scope of Pilot
  • Should cover end to end processes
  • Team
    • Project Lead
    • SAP Expertise – MM/PP/PI, QM, APO
    • Automation Expertise
    • QA/QC
    • Integration/xMII
    • Plant Floor
  • Timeline
    • About 3-4 months
take aways
Take Aways
  • There is an overlap of functionality offered by SAP and MES vendors
    • Perform detail MES requirement mapping with SAP functionality
    • Make the decision up front where the functionality resides (SAP or MES)
    • In many cases SAP + xMII + xApp could meet your requirements
  • For complex processes, compliance and regulatory requirements, consider third party MES solutions
  • xMII is the preferred Integration solution in the SAP landscape
  • Start with an end to end pilot
slide46
0707

Session Code: