Performix Inc: Implementing MES in SAP Landscape
Implementing MES in SAP Landscape
Sham Afzalpurkar
CEO, Performix Inc.
September 26th, 2006
Introduction
• Sham Afzalpurkar, CEO Performix Inc
• About Performix
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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
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Overview of MES
Justifying MES
Developing MES Strategy
MES Architecture
Integration Strategy
Implementation Plan
Lessons Learned
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?
• 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
• Core
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Material and Production Tracking
Material Handling and Production Procedures
Resource management and allocation
Production Dispatching
Data Collection
• Extensions
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Compliance
Quality Assurance
Performance Analysis
Detail Scheduling
Document Management
Labor Management
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?
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The World Batch Forum (WBF) has published XML schemas based on the S95 Model B2MML (Business to Manufacturing Markup “Hypertext” Language)
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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
MES vendors offer solutions that overlap functionality offered by SAP
Agenda
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Overview of MES
Justifying MES
Developing MES Strategy
MES Architecture
Integration Strategy
Implementation Plan
Lessons Learned
Justifying MES – Business Drivers
• Visibility of data globally
• Standard processes
• Enable benchmarking and best practices
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Consistent Documentation
Resource Utilization
Accurate and consistent KPI
Seamless Integration
Justifying MES - Benefits
• Increases Operational Excellence
• Lower Operating Costs
• Asset Management
• Reduced Total Cost of Ownership
Agenda
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Overview of MES
Justifying MES
Developing MES Strategy
MES Architecture
Integration Strategy
Implementation Plan
Lessons Learned
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)
Enterprise Performance Reporting
Demand
Planning
Sales &
Distribution
Detail
Scheduling
Resource
Management
Supply Chain Planning
Material
Management
Process
Optimization
Production
Execution
Production
Planning
Recipe
Management
WIP Material
Management
Cost
Accounting
Human Resource
Management
Warehouse
Management
Maintenance
Management
Performance
Management
Production
History
Real-Time
Execution
Real-Time
SPC
Real-Time
Control
Real-Time
Monitoring
Process
Analysis
Quality
Management
Level 4
Business
Planning &
Logistics
Level 3
Manufacturing
Operations
Level 2
Plant Floor
Control
Simple Discrete
Enterprise Performance Reporting
Demand
Planning
Sales &
Distribution
Supply Chain Planning
Material
Management
Production
Planning
Detail
Scheduling
Resource
Management
Production
Execution
WIP Material
Management
Cost
Accounting
Human Resource
Management
Warehouse
Management
Maintenance
Management
Performance
Management
Process
Analysis
Production
History
Quality
Management
ERP
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
Aerospace and Automotive
Complex Discrete
Enterprise Performance Reporting
Demand
Planning
Sales &
Distribution
Supply Chain Planning
Material
Management
Production
Planning
Cost
Accounting
Human Resource
Management
Warehouse
Management
Maintenance
Management
Detail
Scheduling
Process
Analysis
ERP
Resource
Management
Production
Execution
WIP Material
Management
Production
History
Quality
Management
MES Thousands of parts, complex procedures, many products
Some PLCs
Machines & Work Centers
Production Lines
Real-Time
Execution
Real-Time
SPC
Real-Time
Control
Real-Time
Monitoring
Semiconductor
Enterprise Performance Reporting
Demand
Planning
Sales &
Distribution
Supply Chain Planning
Material
Management
Production
Planning
Cost
Accounting
Human Resource
Management
Warehouse
Management
Maintenance
Management
ERP
Detail
Scheduling
Resource
Management
Process
Optimization
Recipe
Management
Production
Execution
Performance
Management
WIP Material
Management
Production
History
Process
Analysis
Quality
Management
many shared resources, complex routing, many products
MES thousands of parts, complex procedures
Some PLCs
Machines & Work Centers
Production Lines
Real-Time
Execution
Real-Time
SPC
Real-Time
Control
Real-Time
Monitoring
Pharmaceuticals & Specialty Chemicals
Enterprise Performance Reporting
Demand
Planning
Sales &
Distribution
Supply Chain Planning
Material
Management
Production
Planning
Cost
Accounting
Human Resource
Management
Warehouse
Management
Maintenance
Management
ERP
Detail
Scheduling
Resource
Management
Process
Optimization
Production
Execution
Recipe
Management
Performance
Management
WIP Material
Management
Production
History
Process
Analysis
Quality
Management
many shared resources, large recipes, many products
MES compliance, complex procedures
SCADA / PCS
Equipment Trains
Flexible Connections
Real-Time
Execution
Real-Time
SPC
Real-Time
Control
Real-Time
Monitoring
Oil & Gas and Bulk Chemicals
Enterprise Performance Reporting
Demand
Planning
Sales &
Distribution
Supply Chain Planning
Material
Management
Production
Planning
Cost
Accounting
Human Resource
Management
Warehouse
Management
Maintenance
Management
ERP
Process
Optimization
Performance
Management
Production
History
SCADA / PCS
Equipment Trains
Fixed Connections
Process
Analysis
Quality
Management
Real-Time
Execution
Real-Time
SPC
Real-Time
Control
Real-Time
Monitoring
Large number of control variables, real-time optimization
MES Functionality
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Dispatching and Production
Resource Allocation
Quality Management
Data Collection
Process Management
Production Tracking and Genealogy
Document Control
Performance Analysis
Operational Detail Scheduling
Dispatching Production
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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.
Criteria
Positioning
Simple Recipe & Tracking
SAP / PP or PPPI and APO
Complex Recipes
MES
Complex Lot Management
Consider xApp
Resource Allocation & Status
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Manage the resources directly associated with control and manufacturing.
Criteria
Positioning
Manual & Simple Procedure SAP PP or PI
Manual & Automated
MES
Data Collection & Acquisition
Obtains operational production and parametric data associated with production
equipment and processes. Provides real-time statuses of production
equipment and processes.
Criteria
Positioning
Discrete &/or low data volume SAP / PP or PP PI
High speed real time data
MES
collection or very high volume
Quality Management
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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
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Criteria
Manual data collection
Positioning
SAP QM
Real time measurements with MES / SAP xMII
simple statistics
Real time measurements with MES / SAP xMII
multi-variable analysis
Process Management
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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.
Criteria
Positioning
Manual
SAP / PP or PPPI
Automated Systems
MES
Complex Recipes
MES
Production Tracking & Genealogy
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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.
Criteria
Positioning
Simple Recipe & Tracking
SAP
Compliance/Traceability
MES or xApp
Performance Analysis
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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
Criteria
Positioning
Simple Manual & Automated
Systems
SAP xMII
Complex Recipes or
Advanced Analysis
MES + SAP XMII
Operations & Detailed Scheduling
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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
Criteria
Positioning
Simple Discrete Processing with a
Large Supply Chain
SAP APO PPDS
Complex, Very Large, Non-linear
Recipes
SAP APO + MES or Consider xApp
Document Control
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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
Criteria
Positioning
Simple Work Flow
SAP
Simple WF and Regulatory
Compliance
SAP / Document Management System
Complex WF with Regulatory
Compliance
SAP + MES+ Document 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.
Criteria
Positioning
Standard HR Functionality
SAP HR
Training Compliance during
execution
SAP/MES
Maintenance Management
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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.
Criteria
Standard PM functionality
Positioning
SAP Plant Maintenance
Real-time Condition Based SAP Plant Maintenance + MES
Maintenance
Agenda
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Overview of MES
Justifying MES
Developing MES Strategy
MES Architecture
Integration Strategy
Implementation Plan
Lessons Learned
SAP MES Architecture
APO
Demand
Planning
SNP
PPDS
Global
ATP
SAP R/3
BW
Materials
Management
xMII
Production
Planning
Quality
Management
Human
Resources
Integration
Intelligence Dashboard
Master & Transaction Data
Plant
Maintenance
S95
xApps/Composite Apps
MES
OPC
LIMS
Historian
PAT
SCADA
Devices
Doc Mgmt
Agenda
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Overview of MES
Justifying MES
Developing MES Strategy
MES Architecture
Integration Strategy
Implementation Plan
Lessons Learned
SAP MES Integration Options
• Use SAP xMII – Preferred
• Build your own XI integration
SAP MES Integration Using xMII
Manufacturing
Intelligence
Dashboards
SAP BI
Other SAP Bus. Solu tions
Enterprise
SAP NETWEAVER
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SAP xMII enables real-time transactional integration
between plant floor and enterprise (SAP ERP) systems
out-of-the box thru:
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Universal Connectivity to the data, functionality and
processes of existing plant floor systems and SAP
Advanced composite application capabilities for creating
automated events, KPIs and alerts, and new
manufacturing business processes
Synchronization of SAP ERP with real-time Plant Floor
Systems and Processes using proprietary and
standards-compliant messages and workflows
Data Services that provide a foundation for
Manufacturing Synchronization and Intelligence
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SAP Manufacturing
(mySAP ERP)
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XI
SAP xMII
Manufacturing Intelligence
Manufacturing Integration
Plant Floor
MES Integration with SAP – Using xMII
PEOPLE
SAP Enterprise Portal
INFORMATION
SAP R/3, SCM, BW…
Integration
SAP xMII
B2MM
L Msg
Use xMII Integration capabilities if S95 Non Compliant
Shopfloor Application – ANSI/ISA-95 Compliance
= SAP
= 3rd Party Application
Agenda
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Overview of MES
Justifying MES
Developing MES Strategy
MES Architecture
Integration Strategy
Implementation Plan
Lessons Learned
MES Deployment Strategy
• Understand the problem you are trying to solve
• The business drivers
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How you deploy has impact on cost and scope
Integration with Process Control and other applications
Change in the business processes
Facility readiness
Analyze manufacturing processes
and develop MES requirements
Map requirements with SAP
Functionality.
Assessment
Map
MES Requirements
Identify gaps
Design
MES Architecture
Develop global processes,
Integration touch points
Detail plan for pilot and rollout
Develop Deployment
Plan
Pilot
Roll Out
Review Pilot results
Start
Ramp-up
Why Pilot?
• Enhance understanding of MES
• Determine how well current requirements fit into an MES
• Validate the Integration strategy
Scope of Pilot
• Should cover end to end processes
• Team
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Project Lead
SAP Expertise – MM/PP/PI, QM, APO
Automation Expertise
QA/QC
Integration/xMII
Plant Floor
• Timeline
• About 3-4 months
Take Aways
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There is an overlap of functionality offered by SAP and MES
vendors
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Perform detail MES requirement mapping with SAP functionality
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Make the decision up front where the functionality resides (SAP or MES)
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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
Session Code:
0707