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SAP Manufacturing Days - Benjamin Abraham Systema
 

SAP Manufacturing Days - Benjamin Abraham Systema

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SAP Manufacturing Days 2013

SAP Manufacturing Days 2013

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    SAP Manufacturing Days - Benjamin Abraham Systema SAP Manufacturing Days - Benjamin Abraham Systema Presentation Transcript

    • 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 19971993 Foundation of SYSTEMA Focus on MESFocus on MES core functions 2002 Focus on howFocus on how core operations activities interact with business operations 2008 RelationshipsRelationships 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 ReportingMes Reporting Process-DB QM-DB Tracking DBTracking -DB PaperScada 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 MESSAP ERP UniversesUniverses 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 benjamin.abraham@systemagmbh.de www.systemagmbh.de