Leveraging the potential of SAP manufacturing: examples from the automotive and electronics industries
Jun 22, 2015
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 [email protected] www.systemagmbh.de