PI Gateway to SAP R/3 Ron Kolz, Gretchen M. Schwenzer, Ph.D OSI Software, Inc.

PI Gateway to SAP R/3

Ron Kolz,

Gretchen M. Schwenzer, Ph.D

OSI Software, Inc.

Why link SAP to plants?Tighter supply chain integration

focus on speed, reduce cycle time• improve customer responsiveness

• planning - capacity, utilization, bottlenecks (how to increase production speed)

Reduce costs - improve operational efficiency optimize maintenance dollars

• identify performance degradation

• usage-based maintenance

RLINK ArchitectureSAP R/3

(PP-PI, QM, PM)

Plant Network/Intranet

Instrument & Control Interfaces

DCS, PLC, etc.

PI Server

RLINK• NT • SQL Server• SAP GUI

PI API

Communication• SAP to RLINK via RFCs • RLINK to PI via PI’s API

RFCs

Production Planning - Process Industries

Benefits of RLINKOSI standard product, SAP certified

Support SAP, Microsoft technology• Reduce risk, cost and errors of interface• Repeatable across enterprise• Rapid plant implementation

Manual entry slow, error prone• Calculations often required• Data volume that can be handled• Automated interface - timeliness of data sent to SAP,

accuracy of data in SAP

1998 AccomplishmentsSuccessful RLINK implementations

• commitments from several large chemical companies to deploy RLINK corporate-wide

RLINK enhancements• SQL Server 7.0 support

• PP-PI “by-products”

QM/PM development completedSapphire, World Batch Forum

1999 Path ForwardWork closer with SAP verticals

• Position RLINK in SAP solution maps

• Plant Centric strategy

Strategic relationships • RLINK implementation partners

• Educate SAP global/national partners

R/3 4.5 certification: PP-PI, QM, PMSAP seminars Q3/Q4Case studies -- measure results of PI/SAP

integration projects

Presentation Objectives

Quick review of SAP modules and Architecture of RLINK

Enhancements to PP-PISAP QM short tutorial1999 Plans and Benchmark PointsOSI Brewery Demo

SAP

RFC Server

Microsoft SQL PI

BAPI Server UserWorkstation

Other Systems

Microsoft Transaction Server DCOM

Transactional RFC Synchronous RFC

Redundancy

SAP PP-PI (PI-PCS) and OSI-PI/Plant Suite

SAP Functionality Process Order creation to meet order requirements Track material inventory Accounting Recipe for material Track cost of production

OSI Functionality Collects and distributes actual data for material consumption and

production and utilities Translates general recipe to batch execution system Maintains history of recipe that was run and reported values to enterprise Graphically presents current and historical data for analysis Combines recipe data with process variables for analysis

PP-PI New Developments Change of Resouce Detection New Instructions PI_PHUST & PI_OPUST SQLServer 7 and VB6 Partial Confirmations Visual Batch Interface PI storage Material and Batch SAP data

Client Focused Developement Product Improvement Company Input

Distributed SAP Gateways Sterling Diagnostics

Language Customization Sumitumo

PI storage of ProcessOrder, SAPMessage alias +++

Dow Corning

Redundancy Servers Janssen Pharmaceuticals

SAP 4.5 extended features Eastman Chemical

ProcessBook Campaign Manager Polimeri

Turning a Production Request into Action

Continuous process - set start date and time and use duration such as shift, day, etc.

Batch Execution System such as Visual Batch, Openbatch

Setting status of tags in PI via Control System, Visual Basic application or other program.

ProcessBook as campaign manager

ProcessBook as Campaign Manager Application

String tags for SAP dataControl System IndependenceView for operations into SQC, PI-BatchHistory PI-BatchActive X control container Graphics and TrendingReal Time DataPortability across company

SAP Equipment (PM-PCS) and OSI PI/Plant Suite

SAP Functionality No. of hours on stream trigger maintenance Alarm limits for equipment trigger maintenance Maintenance scheduling using human resource and stores

constraints

OSI Functionality Consolidates equipment variables for analysis and improvement of

plant performance in conjunction with process conditions Monitors and reports alarms and no. of hrs. on stream to trigger

SAP maintenance Graphical plant view into Plant and SAP data

SAP QM (QM-IDI) and OSI PI/Plant Suite

SAP Functionality Quality of goods receipt In-process quality specification Quality of goods shipped and certificate of analysis Specification Library Company quality test requirements

OSI Functionality Capture data at source Specification disbursed to industrial desktop Integrates Quality data with process data for plant analysis Disburse Quality worklist to plant floor Reporting Flexibility Interface to Lab Systems

SAP QM SAP Terms

Inspection Lot Inspection Point Inspection Plan Usage Decision Validation Closure Original Values (quantity, code, valuation X 2) Sample Values (quantity, code, valuation X 2) Characteristic Values(quantity, code valuation) No of different types of Lab Data requests (23)

Management Cockpit

Role of the Data Historian and ProcessBook in Integration

Collection of raw data from control environment

Performance CalculationsEnvironment for external calculationsAlarming Batch recordsStorage of Calculated DataSingle presentation and user interface for all

data

1999 Benchmark Points

Certification for SAP 4.5 PP-PICertification for QMTransaction Server and DCOM for PMCombined Demo with SAP