Speaker: Klaus Siegemund (Ferrero) Co-Speaker: José ...€¦ · • Budgeting process integration • Cost controlling - Energy cost per product / cost center • Evidence of Green

01.12.2015 Page 1

Speaker: Klaus Siegemund (Ferrero)

Co-Speaker: José Iglesias (Ciber)

Oktober 2015

at

01.12.2015 Page 2

Need for a 360° view on manufacturing

Source: SAP AG

01.12.2015 Page 3

Users don´t care about systems and applications

Source: SAP AG

01.12.2015 Page 4

Ferrero Group Facts

Start as a pastry shop in Alba (Italy, Piemont)

1946 Company founded in Italy by Michele Ferrero

Today global, non-listed company

Since its foundation in family ownership: CEO Giovanni Ferrero

The Ferrero Group in figures:

• ~ 30,000 employees

• 22 plants and 46 business units

• Turnover 2013: 8 Billion €

Worldwide Plants

01.12.2015 Page 5

Irland

Belgien

Frankreich

Italy

(4 Plants)

Deutschland

Polen

Kanada

Kamerun

Südafrika

Ecuador

Argentinien Brasilien

Türkei

Indien

Sri Lanka

Australien

Russland

Mexiko

China

German Plant Stadtallendorf

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• First and largest production site of Ferrero outside Italy

• Workforce average of 4,000 employees

• Areal has size of 634,000 square meter in total

• High-Bay warehouse capacity for 70,000 pallets, expansion to 90,000 in 2016

• Worldwide Export

Gate

FG Warehouses

R/P Wh.

Power Plant

Chocolate

Factory

Ferrero Brands

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MII in Production and Quality Management

01.12.2015 Seite 13

Production Lines

QM IPC QualityControl

RealtimeMES

QMDashboard

Time Mgmt.

Integrating Automatic Palletizer with MII

01.12.2015 Seite 14

Packing

Machine

Packing

Machine

Palletizer Applicator

PLC

Scanner

SAP

(ERP)MIIDB

MII Web Page

(display

on panel-PC)

Select

Order

Order +

Schema

WINCC

PCo

Show

Orders

Order

Details

01.12.2015 Page 15

Demand to implement EM

As is situation

New Horizons

How shall we begin ?

Simply define your requirements

01.12.2015 Page 16

Simple!

SAP ERP Preventive Maintenance

Continuous Improvement

Hu

ma

n C

ap

ita

l

Org

an

iza

tio

n

Predictive Maintenance

Budget / Investments

Productive MaintenanceMES / SF*

OEE

Dashboard

Production Efficiency

Idea

Managem

ent

MobilitySAP BI

Operations

Energy Management

Energy Management is embedded

01.12.2015 Page 17

* Shop-Floor

01.12.2015 Page 18

Main Intentions

• Increase energy efficiency in our group

• Comparison between production lines

• Tool for identifying potentials for savings

• Benchmarking our own energy improvements

• Overall Corporate Energy Balance

• Profitcenter responsability

• Compare historical periods

• Budgeting process integration

• Cost controlling - Energy cost per product / cost center

• Evidence of Green Production

01.12.2015 Page 19

Expectations

• One central solution covering all functions

• Substitute EXCEL and other island solutions

• International standards and KPI

• Flexible business reports

• Dynamic report creation by user

• Minimum effort for configuration

• Good performance based on high data volume

• Stable and complete data transfer all over the chain

• Less data layers / interfaces

• High integration potential

• Open to OEE, Maintenance, Financial, Controlling

01.12.2015 Page 20

Different Types of Measurements

• Primary– Electric Power (by Source)

– Gas

– Oil

– ……….

• Secondary– Compressed Air

– Steam

– Fresh Water (different temperatures)

– Waste Water

– ………..

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Demand to implement EM

As is situation

New Horizons

Current Solution

01.12.2015 Page 22

Landscape Shop-Floor (Germany)

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SiemensWINCC

FrakoServer

non electricalPowerratefor WinCC

TransformerCounter

~ 800

FrakoServerFrako

Server

electrical

non counted kWhConcentrator (security level)

CompressedAir

Steam

Counter ~ 150

High Power Bus

operationalDatabase

SQL-Server

MII

Landscape Shop-Floor

01.12.2015 Page 24

Acquisition

Systems

Sub system

Priv. Fieldbus

Acquisition

Devices

Ethernet/Field

-bus

PLC

Power Rate

Acquisition

Devices

ProfiNet / Ethernet

Ethernet/Field

-bus

EDMS Interface

Systems

Concentrator

Sub system

Transfer rate

15 min

PLC Power Rate

Up to 6 FIFO buffers for

one S7-300. Each buffer is able

to buffer 20 measuring points

for one day when the EDMS is

not available.

Local Landscape

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MII

MESEDMS

Siemens

WebserviceEC

EEMSOAP

XML

operationalDatabase

SQL-Server

Data accumulated15‘ base

BWU

Manual InputSAP ECCPP-PI

QLI

Pieces

Run- and Idle time

INFOCube

Webservice

PI

External

Local

Global Landscape

01.12.2015 Page 26

From ECC

Central Instance

EC-EEM

Group System

Turkey

MES MII

Mexico

MII

ECC GEA

PI GEA

GER + ITA*

MES

MIIPI OHG

Local Plant Systems

ECC OHG From ECC

Local Instance

Operational

Database

SQL-Server

Operational

Database

SQL-Server

Historian MII

Operational

Database

SQL-Server

Operational

Database

SQL-Server

XI Proxy

MappingProd. Data

async

sync

Tag-listtagnames

tagnames

tagnames

GER Data

MEX Data

TUR Data

Propagate Tagnames

Back to other MIIand ECC

tagnames

Plant Data

Italy

Historian

*temporary

BI

Example – Daily Energy Report

01.12.2015 Page 27

Energy per 100 kg production output

01.12.2015 Page 28

01.12.2015 Page 29

Demand to implement EM

As is situation

Open new horizons!

Main Pillars approaching the future solution

01.12.2015 Seite 30

MII

on

HANA

HANANear

Real Time

Integration

Mobility

HTML 5

Easy

Analytics

Energy Management 2.0 = Energy2Go

Current System Landscape Simplification

01.12.2015 Seite 31

Meter

0,000 Meter Data

Management

System

MES

PCOOPC

MII EM BI

SSCE

HANA

System Landscape Simplification

01.12.2015 Seite 32

Meter

0,000 Meter Data

Management

System

MES

PCOOPC

MII EM BI

Meter

0,000 Meter Data

Management

System

MES

PCOOPC

MII

BI

SSCE*

*SSCE = Self Service Composition Environment

HANA

HANA EM 2.0 – Reporting View

01.12.2015 Seite 33

HANA DB

Big

Data

High Performance availabiliity with MII 15.x

Custom

ApplicationsStandard - SW

Reporting on MII with SSCE

Services

Interfaces

Inte

gra

tion S

cenario

Office Integration(EXCEL)

BI – Design Studio

Lumira

PIC

MII on HANA EM 2.0 BI – Operational View

01.12.2015 Seite 34

HANA DB

Control

Center

MES System(if in place)

WINCC

MII(Version independent)(if in place)

"traditional" Databases

MII 15.xOn HANA

Historian

Dashboards

PCOOPC Scada

PLC

15'

Buckets

Central MII 15.x on HANA – Integration View

01.12.2015 Page 35

PIC

Strong SAP ERP integration

01.12.2015 Seite 36

Master Data stored in ERP

Master Data

Production

Cost Center

Products

Meter Config

SAP ERP

MII – System

Full

Global

Modules

PM

PP

….

PIC =

Plant information

Catalog

Basic settings

Company data

Plant Integration

01.12.2015 Seite 37

PI

MII – System

Full

Global

Modules

MII – System

LOCAL

Function

Modules

MII – System

LOCAL

Function

Modules

MII – System

LOCAL

Function

Modules

MII – System

LOCAL

Function

Modules

PI

Ferrero Plant MII Systems

POC Progress

• System Design Process– Concept with SAP

– BBP finalized

– HANA design finalized

• Ongoing Tasks – Co-Innovation Tasks with SAP ongoing

– Continous approval with stakeholders

– Continous POC systems improvements

– Build additional HANA DB, Views

– Loading Test Data (~ 30th June, 2015)

• POC Evaluation

01.12.2015 Page 38

Project Schedule

01.12.2015 Page 39

Sept - DezMay - AugJan - Apr

2014

Sept - DezMay - AugJan - Apr

2015

POC

MII Upgrade

HANA Setup

Evaluation

Concept Phase

HANA Tools - Power Designer

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SAP Hana Studio

01.12.2015 Seite 41

Reporting Example with LUMIRA

01.12.2015 Seite 42

Reporting Example with LUMIRA

01.12.2015 Seite 43

Reporting Example with LUMIRA

01.12.2015 Seite 44

Benefits

Very simple:

All improvements and constant opimization

is finally saving our Job's because we are

competitive despite high labor costs in Germany

01.12.2015 Seite 45

Thank you!

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