E Wm Material Flow[1]

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E Wm Material Flow[1]

  1. 1. FERRERO MATERIAL FLOW REVIEW OF SAP MATERIAL FLOW SYSTEM. POINTS FOR DISCUSSION Purpose: Understand the SAP offering with respect to Material Flow System available with eWM 5.1 Draft 29/01/2008 P.Villa
  2. 2. FERRERO MATERIAL FLOW POINTS FOR DISCUSSION Material Flow Control Consideration 1 RFC adaptors <ul><li>Is there a separate server that is linked to eWM and PLC via TCP/IP where messages are managed </li></ul><ul><li>If not, is this link then between eWM server and PLC </li></ul><ul><li>If yes, what kind of server hardware and software needed </li></ul>Notes for discussion <ul><li>Does SAP provide a tool to build custom adaptors ? </li></ul><ul><li>The document mentions use of other RFC adaptors possible, are these adaptors provided by third party suppliers, if yes is there a list </li></ul><ul><li>Is there any restrictions with respect to PLC interface, RFC adaptors work with all or is there a particular protocol that must be complied with by the PLC. This is critical in that some warehouses may have equipment that have PLC that are maybe 20 years old. </li></ul>2
  3. 3. FERRERO MATERIAL FLOW POINTS FOR DISCUSSION: FAILURE MANAGEMENT How does system manage failure: eWM Consideration 3 How does system manage failure: PLC <ul><li>How does the PLC react if there is a eWM failure, does the PLC continue as per last message </li></ul><ul><li>Does the PLC stop or does the PLC automatically generates a failure action, therefore instructs machine to move to a pre-defined standby position and wait </li></ul><ul><li>Does the monitor also show TCP/IP failure, ie able to differentiate between a TCP/IP versus PLC failure </li></ul><ul><li>Is it possible to see in eWM a failure related to a specific area controlled by PLC, this may be a segment, Check-point or resource. </li></ul>Notes for discussion <ul><li>What happens when PLC fails, is there are remote actions possible, example re-start the PLC via a message from eWM </li></ul><ul><li>With respect to PLC failure how is the system re-aligned with actual physical position of a pallet, is there a way to manually update/override the eWM with actual situation so that when PLC re-starts the PLC then actions latest message in the queue. </li></ul>4
  4. 4. FERRERO MATERIAL FLOW POINTS FOR DISCUSSION: PLC INTERFACE PLC Channel Consideration 5 Physical layout mapping <ul><li>Is there a limitation on number of PLC channels or any restrictions </li></ul><ul><li>In certain cases a PLC needs instruction even without any related pallet, example is a conveyor that moves continuously or a lift ect…Continuous move resources </li></ul><ul><li>Is it possible to send a eWM message to block a certain segment or check-point in a conveyor or must this be done on PLC which in turn send message to eWm to indicate blocked segment </li></ul><ul><li>In certain cases a sorter needs eWM response to decide if sorter need to deviate to another segment, what king of response performance can be expected from eWM. </li></ul><ul><li>VERY IMPORTANT : is it possible to have gradual replacement of 3party material flow by introducing eWM channel to PLC in steps, this means having some PLC driven by eWM adaptors other by 3° party material flow. This is critical for Ferrero in order to minimize disruption and risk. </li></ul>Notes for discussion <ul><li>Is it possible to represent the physical layout of the warehouse and related automation, example: </li></ul><ul><li>Segment and Check-point for conveyor </li></ul><ul><li>Resources that moves pallet from one CP to another </li></ul>6
  5. 5. FERRERO MATERIAL FLOW POINTS FOR DISCUSSION: PLC INTERFACE PLC programming rework Consideration 7 Conclusion <ul><li>Is there any rework required with respect to PLC programming to use the message adaptors </li></ul>Notes for discussion 6 <ul><li>Are there any live sites ? </li></ul><ul><li>Is there any documentation other that current Material Flow Presentation document. </li></ul><ul><li>From a functionality/usage/technology how does SAP Material Flow system compare to Siemens prox4 </li></ul><ul><li>What about licensing costs, is this covered by SCM 5.1 eWM ? </li></ul><ul><li>Will there be any reporting KPI to indicate: </li></ul><ul><ul><li>Number times resource XX has had failure </li></ul></ul><ul><ul><li>Performance KPI of a ASRS </li></ul></ul>

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