SAP Manufacturing Days - Benjamin Abraham Systema

Leveraging the potential of SAP manufacturing: examples from the automotive and electronics industries

AGENDA

• Who we are - SYSTEMA

• What is the potential of a MES

• Project examples

• Summary

About SYSTEMA

• A global specialist in business process automation and integration of High-Tech Manufacturing IT

• 20 years experience in discrete manufacturing

• Privately owned company, independent

• 130 employees in 3 offices – Dresden, Germany (head quarter)

– Regensburg, Germany (branch)

– Corvallis, OR, US (subsidiary)

• ISO 9001:2008 certified

What we do

• Increase of productivity and efficiency

– Vertical integration from ERP to Shop Floor Equipment in Semiconductor, MEMS, Biotechnology and Automotive Industries

• MES consulting, implementation, extension & migration

– Workstream

– Promis MES

– FAB300

– SiView

– SAP ME/MII

– Eyelit

– SmartFactory

– acp IT Synapse

A strong partnership

• SYSTEMA is a strategic partner for manufacturing

– 20 years in MES business including equipment integration, recognized industry expert in MES consulting and migration

– World's first implementation of SAP ME V6.0 in high-tech industry

– Active participation in SAP ME V6.1 Ramp-Up Program

– Co-Innovation partner

– Successful SAP ME implementations in several industry sectors

The times are changing

• Finding Gold in Manufacturing Operations

http://en.wikipedia.org/wiki/File:Gullgraver_1850_California.jpg

http://en.wikipedia.org/wiki/File:Kalgoorlie_The_Big_Pit_DSC04498.JPG

Kalgoorlie Super Pit, Australien 2009

(3.8 km x 1.5 km x 600m)

Need for MES – times are changing

Paperless Production

• On demand, flexibility

• Optimization for high product mix, small lot sizes

• Increased automation level

Digital business process, e-Manufacturing

• Integrated and distributed SCM

• Big data

• Effective WIP control

Active Quality Management

• Auditable material tracking (multi-site)

• Active process execution

• Integration of SPC, APC

MESA - MES Model Evolution

1992

1997 1993

Foundation of

SYSTEMA

Focus on MES Focus on MES core functions

2002

Focus on how Focus on how core operations activities interact with business operations

2008

Relationships Relationships between strategies, enterprise-level operations, and plant operations

The MES reality

• Legacy systems are reaching end-of-life

• Complex system landscapes with highly customized solutions -> high TCO

• Basic and asynchronous vertical integration between manufacturing and ERP

• Custom interfaces between Master Data Systems and MES

The MES reality

ERP ERP Reporting

MES Mes Reporting Mes Reporting

Process-DB QM-DB

Tracking DB Tracking -DB

Paper Scada Worker

SAP is closing the gap

SAP ERP

Analysis & Reporting SAP BObj

MM PM QM

PP

SAP Manufacturing SAP MEINT

SAP ME, SAP MII SAP PCo, SYSTEMA ECo

SAP Mobile Apps

Project Achievements

Traceability

- Stepwise traceability concepts

- Different traceability levels

- D-part support

Traceability

- Stepwise traceability concepts

- Different traceability levels

- D-part support

Quality

- Collection of quality data

- Test device management

- Rework station

- Corrective Actions

Quality

- Collection of quality data

- Test device management

- Rework station

- Corrective Actions

Efficiency

- Equipment efficiency

- Cycle times

- Data collection and KPI reporting

- Visualization and production metrics

- Maintenance

Efficiency

- Equipment efficiency

- Cycle times

- Data collection and KPI reporting

- Visualization and production metrics

- Maintenance

Scalability

- Multi site support

- Release compatible extensions and updates

- Service oriented architecture

- Data consistency

- Single source of truth

Scalability

- Multi site support

- Release compatible extensions and updates

- Service oriented architecture

- Data consistency

- Single source of truth

Reporting

Analysis

Reporting

Analysis

SAP Manufacturing in the industry

Case 1 – Sensor production

• 250 products, 20 - 80 process steps

• Master data (BoM) consistence between ERP and shop floor

• Problem misprocessing,

– Manual input leads to errors

– Documentation based on runsheets/travellers

– Scrap rate to high

• No automated data analysis

– Not enough data

– Decentralized data

– Missing link between tracking and process data

Case 1 – Solution Architecture

Recipe Management

Equipment Integration Suite

• Material verification

• Recipe select / verification

• Equipment status

• Track in / out

• Data collection

• Errors

SAP ME/MII

Case 1 – Sensor production

• Results

– Increased yield by 5 %, reduced scrap

– 100% auditable traceability

– Process and material tracking

– Proven quality

– Automated corrective actions

• ROI after 10 months

SAP Manufacturing in the industry

Case 2 – automotive components

• Operator can put material in many operations on rework/hold

• Rework can be performed on by shift leaders

• Delayed information for blocked material

• No terminal at every rework station

– Missing documentation

– Traceability problems

Case 2 – automotive components

• Connect SAP ME to mobile devices

• Monitor shop floor activities on the go

• Set free existing potentials

• Activate mobile control, analysis and reporting

Case 2 – automotive components

• Always notify the right person

• Efficiently distribute operator workload

• Documented rework -> fullfillment for D-parts

• Acceptance on the shop floor

• Enhance traceability =

• Increase machine utilization =

• Increase manpower availability =

SAP Manufacturing in the industry

Case 3 – power electronics

• Distributed production, multiple sites

• Different MES, different reporting systems

• No consistent metric for OEE, Yield, KPIs

• Big data volumes, process data

• No combined data analysis for different data sources possible

BObj as fully integrated BI Platform

SAP Business Objects

ME-BObj Reports

Explorer

SAP-ERP

Reports

Appl. Specific

Reports

Customer defined report templates, multi-site

ODS BW NON

SAP NON

SAP

Universes

SAP ME MES SAP ERP

Universes Universes

CAQ

Case 3 – power electronics results

• Transparency and comparable sites

• One Reporting system – multi site reports

• Same KPI metrics – based on standards like VDMA, SEMI

Key points in MES projects with SAP Manufacturing

– Establish fully traceable production through SAP Manufacturing Execution

– Integrate people, machines, and processes on the shop floor to create greater transparency and control

– Implement fully integrated seamless data transfer between shop floor and ERP

– Multi-site data analysis and reporting are integrated features, even for legacy applications

– Consistent creation, versioning, and management of BoMs between ERP and MES becomes reality

– Paper-based workflows can be replaced by dynamic production control combined with precise data collection

When will you take advantage of SAP Manufacturing?

Benjamin Abraham Senior Manager benjamin.abraham@systemagmbh.de www.systemagmbh.de