SAP Manufacturing Days - Achim Krueger SAP
 

SAP Manufacturing Days - Achim Krueger SAP

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SAP Manufacturing Days 2013

SAP Manufacturing Days 2013

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SAP Manufacturing Days - Achim Krueger SAP SAP Manufacturing Days - Achim Krueger SAP Presentation Transcript

  • SAP’s Idea to Performance Strategy Innovation in Operational Excellence Dr.-Ing. Achim Krüger – VP, Operational Excellence Solutions – SAP AG s'-Hertogenbosch, September 12th, 2013
  • © 2013 SAP AG. All rights reserved. 4 SAP’s Idea to Performance Strategy Innovations in Operational Excellence Boundary Conditions What is "Operational Excellence"? Innovations Summary and Conclusion
  • © 2013 SAP AG. All rights reserved. 5 SAP’s Idea to Performance Strategy Innovations in Operational Excellence Boundary Conditions What is "Operational Excellence"? Innovations Summary and Conclusion
  • What is influencing the way we are doing business? Smart assets Internet of Things Machine- to-machine Mobilization Shop-floor to top-floor Integrated value chains Social networks Sustainability Big data Knowledge management Operational Integrity
  • © 2013 SAP AG. All rights reserved. 7 SAP’s Idea to Performance Strategy Innovations in Operational Excellence Boundary Conditions What is "Operational Excellence"? Innovations Summary and Conclusion
  • © 2013 SAP AG. All rights reserved. 8 Idea to Performance Value Map of End-to-End Solutions Operational Excellence Responsive Manufacturing Repetitive Manufacturing Make-to-Order Manufacturing Engineer-to-Order and Project Manufacturing After-Market ServiceSustainable Innovation Integrated Product Development (DI) Integrated Product Development (PI) Continuous Product and Service Innovation Environment, Health and Safety (aka Operational Risk Management) Enterprise Portfolio and Project Management Capital Portfolio and Project Management Commercial Project Management IT Portfolio and Project Management Outsourced Manufacturing LEAN Manufacturing Manufacturing Visibility and Performance Product Safety and Stewardship Energy and Environmental Resource Management Asset Visibility and Performance Quality Management and Compliance Asset Operations and Maintenance Multichannel Customer Service Field Service Management Complaints, Returns, and Depot Repair Management Service Contract Management
  • © 2013 SAP AG. All rights reserved. 9 17%Higher return on assets where asset management systems are fully integrated, with inventory management, MRO, purchasing, engineering and finance. Source: SAP Performance Benchmarking 40%Higher employee productivity when mobile access is provided to employees across all levels. Idea to Performance – Operational Excellence Quantifying the Impact 61%Higher revenue from new products when portfolio goals are communicated throughout the organization and results are measured and reported 79%Lower recordable accident frequency with establishment and monitoring of strong safety measures for people and assets. 40%Lower scrap when quality system supports supply chain planning, root cause analysis, quality notifications, and advanced product quality planning.
  • © 2013 SAP AG. All rights reserved. 10 Business priority: Operational Excellence Idea to Performance Operational Excellence Value Map Asset Visibility and Performance Asset performance measurement Asset improvement programs Optimize maintenance and plant operations Asset Operations and Maintenance Asset planning and scheduling Operations and maintenance Service procurement Spare parts management Mobile asset management Energy and Environmental Resource Management Energy Transparency and Performance Management Energy and Environmental Initiatives Management Emissions Management Environmental Regulatory Compliance Environment, Health and Safety (aka Operational Risk Management) Incident management EHS risk assessment Management of change Maintenance worker safety management Work permit management Quality Management and Compliance Corporate quality Quality planning and control Quality operations
  • © 2013 SAP AG. All rights reserved. 11 SAP’s Idea to Performance Strategy Innovations in Operational Excellence Boundary Conditions What is "Operational Excellence"? Innovations Summary and Conclusion
  • © 2013 SAP AG. All rights reserved. 12 Idea to Performance SAP Innovations Applications SAP HANA Mobile Analytics Cloud 80% Of decision makers think access to the right information at the right time is critical to their business. Source: SAP Performance Benchmarking
  • © 2013 SAP AG. All rights reserved. 13 Idea to Performance – Operational Excellence End-to-End Solution EH&S (aka Operational Risk Management) Incident Management Identify and resolve safety issues and learn from incidents. EHS Risk Assessment Reduce safety and environmental incidents with proactive risk assessments. Management of Change Manage operational changes with thorough review, risk mitigation, and documentation approval. Maintenance Worker Safety Provide clear safety-related instructions for the maintenance worker. Work Permit Management Control maintenance and operations work through permits and lock-out/tag-out processes. Innovations:  SAP Environment, Health, and Safety Management  SAP Management of Change  SAP EHS Safety Issue mobile app  SAP EHS Regulatory Content  SAP EHS Regulatory Documentation  Embedded analytics for EHS Management  Additional mobile apps for EHS Management* * planned application
  • © 2013 SAP AG. All rights reserved. 14 Idea to Performance – Operational Excellence Executive insight & holistic view of sustainability performance Corporate Individual Site Management Incident Mgmt Management of Change Worker Safety Risk Assessment Work Clearance Management Mobile Explorer Sustainability Perf Mgmt Audit Mgmt
  • © 2013 SAP AG. All rights reserved. 15 Operational Risk Management Worker Safety – overall concept Solution Today Work Clearance Management (WCM) Create risks and responses Assign risks to maintenance objects Safety plan in ERP PM Risk management* Work clearance management*Worker safety Worker safety in job execution * optional
  • © 2013 SAP AG. All rights reserved. 18 Solution enhancements Key benefits Operational Risk Management SAP Management of Change  Effective management of change for changes of products, procedures, processes, equipment, and so on  Consistent and auditable management of changes  User-friendly UI that motivates all employees in a plant to communicate change requests  Timely and effective completion of reviews, approvals, and all actions to implement the change (update documentations, trainings, master data, and so on)  Easier-to-customize solution and shipment of templates to decrease implementation and adoption costs  A product independent of the releases of SAP Business Suite; a networked application on premise  Streamline different change processes across the company and make them more efficient  Ensure that employees follow a company´s procedures and record change requests  Increase visibility and share best practices to reduce incidents, ensure compliance, and mitigate risks  Ensure that a structured change-process occurs that complies with all regulatory and other requirements Solution Today SAP Management of Change 1.0
  • © 2013 SAP AG. All rights reserved. 21 Operational Excellence End-to-End Solution Quality Management and Compliance Corporate Quality Gain visibility into quality operations across plants, meet your corporate quality goals, and comply with internal and external standards. Quality Planning and Control Achieve “quality by design,” integrate quality-related information with other business units, and enable a continuous improvement process. Quality Operations Help ensure efficient testing and exception handling, release safe and in-spec products, and comply with standards and regulations. Innovations:  SAP Quality Issue Management  SAP ERP Quality Issue mobile app  Enterprise Dashboard for Quality Management* * planned application
  • © 2013 SAP AG. All rights reserved. 22 Idea to Performance Operational Excellence – Quality Management and Compliance SAP Quality Issue Management (QIM) Quality Management with SAP Quality Engineering PLAN SAP QIM Basic Capabilities of SAP QIM:  Create and process issues  Monitor issues across multiple sources  Integrate SAP & non-SAP systems  Handle all related activities Quality Assurance DO Quality Improvement ACT Quality Control CHECK Customer ComplaintsNon-ConformancesR&D Deviations Supplier issues QIM Design Plan ServiceMakeImagine
  • © 2013 SAP AG. All rights reserved. 23 Operational Excellence End-to-End Solution Asset Visibility and Performance Asset Performance Measurement Measure performance of assets as well as asset systems and processes used to manage them. Identify improvements to achieve organizational goals. Asset Improvement Program Prioritize improvements and ensure deployment of critical resources to manage improvement programs that lead to high return on investments, while lowering related risks. Optimized Operation and Maintenance Evolve and optimize asset management strategies to ensure that asset capabilities meet operational demands throughout their lifecycles. Innovations:  SAP Asset Data Quality rapid-deployment solution (part of Asset Portfolio and Commissioning)  SAP Condition based Maintenance rapid-deployment solution  SAP Asset Analytics rapid-deployment solution  SAP Predictive Analysis  Predictive Maintenance and Service* * planned application
  • © 2013 SAP AG. All rights reserved. 24 Operational Excellence – Asset Visibility and Performance Improve asset performance with SAP Asset Analytics Solution today Scope Key benefits  Pre-configured EAM Analytics based on a robust and scalable platform  Native integration with EAM master and transactional data  User-friendly score card to measure performance  Configurable drilldown reports and dashboards  Simplified impact analysis and guided root cause analysis  Online or offline review of KPI using briefing books  Quick implementation of some of the most important key performance indicators  Quick business decision and problem resolution  Easy way to bench mark performance and roll out best practices to gain competitive advantage  Identify bottlenecks and collaboratively resolve them to support continuous improvements in asset performance
  • © 2013 SAP AG. All rights reserved. 25 Scope Key benefits Real time Information System Specification and Characteristics Manually inspected information Preventive and Corrective maintenance Physical system of asset Operational Inputs Operational Outputs Virtual system of asset Operational forecasts Virtual forecasts Operational Excellence – Asset Visibility and Performance Maintenance predictive analysis using in-memory analytics Planned innovations  Leverage in-memory analytics (the SAP HANA platform) to predict failure based on a certain confidence and risk level  Group multiple asset health monitors  Identify trends in heath indicators for assets  Predict optimum time at which inspection as well as maintenance should be planned, based on trends in historical failures, age, utilization, environment, and other parameters  Increased availability of assets  Improved compliance  Reduced cost  Improved asset safety Next inspection
  • © 2013 SAP AG. All rights reserved. 26 Scope Key benefits Operational Excellence – Asset Operations and Maintenance Integrated CAPEX and OPEX planning and lifecycle costing of assets Planned innovations  Use of in-memory analytics (SAP HANA) for analyzing items that are critical for reducing the cost for maintenance  Replacement and repair analysis  Forecasting of operational cost  Evaluation of lifecycle cost  Provide real-time visibility of asset performance and its financial impact  Use predictive methodology in reducing risk  Improve or sustain the capability of assets and identify the impact they have on CAPEX  Proposing efficient ways to reduce OPEX and make an investment (CAPEX) decision based on life cycle costs Historical orders and resource utilization Historical asset performance Master data Preventive maintenance plants Shutdown turnaround and cutages Estimated corrective maintenance Estimated breakdown maintenance ERP Dashboards Explorer BPC Reporting analysis and planning Optimistic, realistic, and pessimistic utilization plans Repliciation engine Extractors SAP HANA 1. Critical analysis 2. Forecasting cost 3. Projecting variance with time
  • © 2013 SAP AG. All rights reserved. 27 SAP Enterprise Asset Management on HANA What is new and what is coming…  Improved scheduling of maintenance plans  Real-time material planning  Maximize productivity of complex projects Accelerated ERP transactions  Provide views and query for most PM objects  Queries and calculation views for online reporting / analysis  Improved SAP Asset Analytics with BW on HANA (planned)  SAP Condition-Based Maintenance (CBM) to collect real time shop floor data for analysis on HANA HANA analytics and reporting HANA-based applications (planned)  Use Predictive Analysis for forecast of cost and spare parts  Predictive maintenance to forecast potential failure based on real time data  Predict cost of maintaining assets and prepare CAPEX and OPEX budgets  Energy and Environmental Resource Management (EERM) with HANA analytics to manage your most important invisible asset - energy
  • © 2013 SAP AG. All rights reserved. 28 Operational Excellence End-to-End Solution Asset Operations and Maintenance Asset Planning and Scheduling Help customers better plan their maintenance activities. Operations and Maintenance Optimize execution of maintenance activities. Service Procurement Standardize and automate the complete service procurement process for all plant maintenance services with integrated SAP software. Spare-Parts Management Automate tracking and analysis of parts inventory monitoring, replenishment, and forecasting data. Mobile Asset Management Improved safety and productivity with relevant information that’s accessible anytime, anywhere – online or off. Innovations:  SAP Condition based Maintenance rapid-deployment solution  SAP Multiresource Scheduling rapid-deployment solution  SAP Work Manager  SAP Rounds Manager  SAP Inventory Manager
  • © 2013 SAP AG. All rights reserved. 29 Scope Key benefits Operational Excellence – Asset Operations and Maintenance Rapid-deployment solution for condition-based maintenance (CBM) Solution today  Integrates with shop floor systems  Prebuilt best practices to manage equipment based on their conditions in real time  Identification and prioritization of current maintenance tasks based on equipment conditions  Prebuilt operator interface to collect utilization as well as its performance, current capabilities, and possible deteriorations  Providing example content to store condition data in SAP HANA and visualize it with SAP Visual Enterprise to enable a quick decision for corrective measure  Reduced unplanned down time  Improved availability of assets  Reduced cost of maintenance  Standard content to implement condition-based maintenance quickly with rapid-deployment methodology
  • © 2013 SAP AG. All rights reserved. 30 Operational Excellence – Asset Operations and Maintenance Recent Enhancements to the SAP Multiresource Scheduling application SAP Multiresource Scheduling rapid-deployment solution Solution today Scope Key benefits  Transparency of the resource and demand planning situation  Profitability by reducing nonproductive working times  Cross-organizational alignment in the resource planning process  Efficient planning of high volumes of resources and demands  Flexible reactions to changing demands and planning requirements  Monitoring daily execution  Integration with other processes and SAP applications  Compliance with service-level agreements  Have a comprehensive and up-to-date planning overview  Improve planning efficiency  Establish a user-friendly and graphical planning board  Enforce adherence to service-level agreements  Reduce the idle time of your service staff and tools by optimizing resource utilization  Streamline planning processes  Reduce downtime of assets  Enhance service quality
  • © 2013 SAP AG. All rights reserved. 31 Scope Key benefits Operational Excellence – Asset Operations and Maintenance Future Improvements in SAP Multiresource Scheduling Planned innovations  Additional print functions and forms  Additional data fields and features to complement the business process together with the plant maintenance and project functionality of SAP ERP  Functions to leverage work center capacities  Enhanced relationship handling in the planning board  Usability within the continuous improvement process for the SAP Multiresource Scheduling application  Increased resource utilization  Increased transparency of resource utilization across organizational units  Optimization of resource assignment according to travel times, priorities, and qualifications  More efficient resource request handling  Increased customer satisfaction
  • © 2013 SAP AG. All rights reserved. 32 Operational Excellence – Asset Operations and Maintenance Overview on solutions for Mobile Asset Management Boost productivity, reduce cost, gain a 360-degree view of operations, and increase asset longevity by enabling mobile operation of SAP Enterprise Asset Management Work order management (SAP Work Manager mobile app):  Facilitated work order flow across a variety of mobile devices  Cross-application time sheet (CATS) – time and attendance  Online and offline mode Maintenance and operator rounds (SAP Rounds Manager mobile app):  Measurement and pointer readings  Rounds by equipment type or name  Creation of notifications on the spot Inventory management (SAP Inventory Manager mobile app):  Perform physical and cycle counts quickly  Check material availability while on the job  Pre-pick spare parts based on work orders
  • © 2013 SAP AG. All rights reserved. 35 Scope Key benefits Operational Excellence – Asset Operations and Maintenance Road map of enhancements for Mobile Asset Management  Further integration of mobile apps  GEO-Enablement: Geospatial visualization on the mobile device as part of work order management process  Support of processes of SAP Linear Asset Management  Integrated SAP Visual Enterprise Viewer for animated work instruction and spare parts selection processes  Integrate with processes from worker safety and work clearance management  Enhanced support for inspection processes  Additional standard languages besides English  UI and navigation enhancements  Global applicability across many industry  Increased ease of use  Boosted productivity  Reduced cost  A 360-degree view of operations  Increased asset longevity
  • © 2013 SAP AG. All rights reserved. 37 Integration of all needed information into a one-stop shop for the asset management & maintenance people
  • © 2013 SAP AG. All rights reserved. 38 Operational Excellence End-to-End Solution Energy and Environmental Resource Mgmt Energy Transparency and Performance Management Sharpen visibility of energy costs, consumption, and emissions across assets, individual sites, and the entire enterprise. Energy and Environmental Initiatives Management Consolidate, evaluate, and prioritize the portfolio of energy and emissions projects. Emissions Management Manage greenhouse gas and other air or water emissions for voluntary or regulatory disclosure. Environmental Regulatory Compliance Improve adherence to regulatory reporting guidelines, reducing the risk of penalties for noncompliance. Innovations:  SAP Energy and Environmental Intelligence, powered by SAP HANA
  • © 2013 SAP AG. All rights reserved. 39 Energy and Environmental Resource Management Software Component Overview Energy Transparency & Performance Management SAP Energy and Environmental Intelligence, powered by SAP HANA Regulatory Compliance (SAP EC) SCADA / DCS / Historians Smart meter / BMS systems Surveys / manual data collection Utility invoices Initiatives Management (SAP PPM) Thresholds and Alerts Hierarchies (Corporate, Site & Asset Level) Calculation Engine & Library Interval Data (Consumption, Costs, Emissions…) Cost Mgmt, Asset Mgmt, Production, etc. (SAP ERP) Real World Integration & Connectivity (SAP MII) Energy and Environmental Resource Management optional
  • © 2013 SAP AG. All rights reserved. 40 SAP’s Idea to Performance Strategy Innovations in Operational Excellence Boundary Conditions What is "Operational Excellence"? Innovations Summary and Conclusion
  • © 2013 SAP AG. All rights reserved. 41 Idea to Performance – Operational Excellence Summary and Conclusions Operational Excellence aims on total visibility about asset performance, environment, health & safety risks, energy consumption, and quality. SAP' solutions in the categories of applications, SAP HANA, mobile, analytics, and cloud help control cost, risk, and performance. Users in manufacturing and operations get access to the information they need, in the format they need it, and at the site they need it. SAP has added a lot of innovation and integration between its solutions for Operational Excellence, yet more to come. SAP will develop and deliver further solutions in intense collaboration with its customers and partners. Finally, let's keep it with Charles Darwin: "It is not the strongest nor the most intelligent of species that survives, but the one that is most adaptable to change."
  • Questions? More information: http://www.sap.com/idea-performance http://service.sap.com/roadmap http://scn.sap.com http://www.sap.com/solutionexplorer