Presentation for the opening of the SAP Leonardo Center in Paris with the last innovations around MIPM and Digital Transformation from Faurecia Group Information Systems

1. SAP Leonardo as a backbone
to support the industry 4.0
approach within Faurecia Jose GASCON /Eric GODARD

2. Key figures
2
35
countries
98,700
employees
300
sites
€15.6 billion
of value added
sales*
> 6,000
engineers
and technicians in R&D
30
R&D centers
636
programs
in development
501
patents filed in 2016
* Value-added sales: Total sales less monoliths sales - 2016 figures

3. A global leader with diverse customer portfolio
3
SALES BY CUSTOMER
Ford
GM
BMW
Others
VW Group
FIAT-Chrysler
PSA
Hyundai Kia
2016
Cummins
Daimler
19.1%
16.9%
15.2%13.0%
Renault-Nissan
Audi A5
Sportback-2016
F250 Super Duty
Series 2017
Hyundai Ionic
Peugeot 5008
Renault Grand Scenic

4. Global leader in its 3 Business Groups
4
€4.8 billion €4.2 billion€6.6 billion
Technologies for emissions
control, energy recovery,
weight reduction,
acoustic performance
Seat structures, manual
and electric seat mechanisms,
comfort products and systems,
trim, complete seat assembly
Instrument panels,
door panels, center consoles
and acoustic modules
INTERIORS CLEAN MOBILITYSEATING
32,400
employees
21,200
employees
37,400
employees

5. Faurecia’s Digital Journey
5
before
2015 2015 2016 2017
Digital Enterprise
4 digital
streams
Digital
Transformation
5 digital
streams
Innovations
Get value from digital
Continue digital innovation
Digital in company DNA
Faurecia Excellence
System
…
Pilot mode
Innovation
200 initiatives
42 PoC
Paper culture

6. Digital Transformation at Faurecia focuses on 5 value streams, with innovation
to fuel them
Digital
innovation
Cost Value
Cost Value
starting 2017
Top line Value tomorrow
employee attractivity
& Being Faurecia
Enhanced E2E working
methods
Today focus

7. Stream #1: Digital Operations
7
Light Guide
Systems
Automatic
guided vehicles
Collaborative
robots
Logistic Network
Optimization
Digital Management
Control
MIPM
(data analytics)
Plant Maintenance
Mobility
Traceability
(RFID)
Innovation initiatives to prepare 2018+ new standards
(digital watch, POCs, co-innovation, ecosystem orchestration)
digital
standards8
+

8. 3 mn …
8
… to illustrate our Industry 4.0 journey

9. Manufacturing operations focus: benefits and use-cases
Why did we implement a MIPM initiative?
Increased
productivity
and quality
 Reduced Non-OEE*
 Anticipation of non-quality with alerts and recommendations
 Non-quality reduction by connecting ERP data and shop floor data
and using new technology
Plant
Benchmark  Comparison of machines performance within several plants
Reduction
of production
costs
 Reduction of scrap rates, defect rates and raw materials waste
 Improvement of product quality (less deviations)
 Optimization and reduction of energy use
Reduction
of breakdowns
and downtime
 Reduce maintenance costs and extra freight transportation costs
 Minimize unscheduled downtime and breakdowns
 Increased equipment life cycle
(*) OEE stand for Overall Equipment Effectiveness

10. SAP Leonardo PCo to
Apache Kafka
New Destination
Jose GASCON

11. Analytics
MI
Analytics
PM
Collect and qualify data
Too many protocols to adapt optimally to each use case
SAP MII/PCo
 A data lake is a method of storing data within
a system or repository
 Data is collected from PLC via SAP PCo:
 High frequencies pulling every 30ms and
locally staged to be transmitted in batch.
 Low frequencies pulling every 1s to 5s,
and sent directly via PCo without staging.
 OPC server (Open Platform Communications):
communication between PCO and machines
 PLC (Programmable Logic Controller):
industrial computer control system that
continuously monitors the state of machines
OPC server
OPC client (SAP PCO)
SAP MII
SAP PI/PO
Data Lake
REST
?
?

12. Faurecia and SAP Co-innovation
Idea Discover Design Deliver
Identify most valuable
business use cases
Collect pain points
of as-is process and discuss
possible solutions
Design to-be process
together in a prototypes
Co-developing prototype for
customer specific challenge

13. SAP Plant Connectivity (PCo)
SAP Plant Connectivity (PCo) is SAP’s
standard connectivity solution between
shop floor and business systems.
Reliable routing of data between systems.
Supports both event-driven notifications,
for example, data tag changes at logic
controllers, and routing them to business
systems, and queries (read and write) of
data tag values from logic controllers.
Why not a new destination directly to Big
Data? SCADA
Historians Third Party
Business
Systems
Logic
Controllers
Big Data
Clusters
Machines
and
Devices
SAP Plant
Connectivity
(PCo)
SAP
Business
Suite
SAP Cloud

14. Data Lake
Analytics
MI
Analytics
PM
Collect and qualify data
Architecture with a Kafka as single message oriented middleware
SAP MII/PCo
Kafka new PCo Destination
 Both high frequency and low frequency data
collection are managed the same way.
 Low-latency ingestion of large amounts of event
data allows both use cases (real-time and batch
ingestion) being managed the same way:
micro-batches from 1s to 10s.
 Compression allows a much more efficient use of
the available bandwidth.
 Remove intermediate single point of failures.
Next Steps
 Evaluation of SAP Dynamic Edge Processing.
 An step forward to bring real-time analytics
closer to the data.
 Reduce the volumes to be stored centrally to the
significant levels.
OPC server
SAP PCo
SAP MII Throughput improved from
10 msg/s to 500 msg/s by node
SAP Dynamic
Edge
Processing

15. Conclusion
❶ Single point of entry
 reduce the load on backend Business systems
like MII and rely on MoM PCo + Kafka
 distribute the process data to all components
❷ Storage capacities
 centralization of data in one place
 available for any type of request from MI/PM
❸ Analytics & discovery
 computing power for custom analytics
 direct analytical functions
 visualize the results concretely
❹ Data Publishing
 compatible with current & new partners
 custom data visualization
Big Data
Predictive
Maintenance
Manufacturing
Intelligence
Real Time Process DataFlat files
External
Databases