Post on 20-Aug-2015
Confidential // Neoris 1 Confidential // Do Not Reproduce without prior written permission from Neoris
Neoris USA
Sauder Woodworking: Enhancing The Lean Journey With SAP MII
November 1, 2013
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Index
Welcome And Introduction
Welcome And Introduction
About Neoris
SAP MII Solution Overview
Sauder Woodworking MII Implementation
Closing and Q&A
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Welcome And Introduction Presenters
Tom Taylor Director, Neoris
Peter Molina Director, Neoris
Moderator
Antonio Vera Subject Matter Expert,
Neoris
Pam Vocke Implementation Services
Manager, Sauder
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Index
About Neoris
Welcome And Introduction
About Neoris
SAP MII Solution Overview
Sauder Woodworking MII Implementation
Closing and Q&A
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Neoris - Who We Are…
Significant accomplishment of growth :
2nd in IT consulting in Latin America
Largest IT consultancy in Mexico
SAP Global Partner (only Latin America based)
2012 SAP Pinnacle award for quality
Forrester rated as “Strong Performer” in Forrester Wave for SAP Services Providers
Top 10 Best Performing IT Outsourcing Service Provider, Global Services 100
Best Nearshore Outsourcing Company from Latin America, Brown-Wilson Black Book
A Business and IT Consulting Company with a Global Footprint
Neoris Offices
Neoris Solution Centers
Nearshore Outsourcing Solution Centers: Culiacan, Monterrey, Buenos Aires, Santa Fe, São Paulo, Madrid Budapest and Manila
Market Recognition
Employees: Over 3,500
Founded: 2000
Offices: 20
Corporate Office: Miami, FL USA
Majority owned by CEMEX (NYSE: CX); Market cap of US$15 Billion
Argentina (Buenos Aires, Rosario, Santa Fe)
Brazil (Rio de Janeiro and Sao Paulo)
Chile (Santiago)
Colombia (Bogotá)
Hungary (Budapest)
Mexico (Culiacan, Monterrey and Mexico DF)
USA (Miami and Dallas-Fort Worth)
Spain (Madrid and Barcelona)
United Arab Emirates (Dubai)
Philippines (Manila)
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Further Recognition And Distinction Awards
2013 – SAP Manufacturing Mobile Innovation Challenge at SAPinsider Conference in Las Vegas
2011 – Neoris ranked #1 at the SAP MII SI Partner Landscape
2010 – SAP Strategic Reference Award for the MII project at USIMINAS (Brazil)
2010 – ASUG Impact Award for the MII project at USIMINAS (Brazil)
2008 – ASUG Impact Award for the MII project at Fosfertil (Brazil)
2008 – SAP Strategic Project for the MII project at CINTAC (Chile)
2007 – SAP Innovative Project for the SAP xMII project at Petrobras (Brazil)
2006 – SAP Strategic Reference Award for the xMII project at PEMEX (Mexico)
“Looking to use SAP MII? Consider work by Neoris to make SAP MII a reality. With a history of improving SAP implementations in South American operations, we’re impressed with the company’s ability to make SAP MII vision a reality.”
Gartner Cool Technologies for Improving Consumer
Products Value Networks
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MII - Leadership And Experience (45+ Projects Implemented!)
2006 2007 2008 2009 2010 2011 2012
Konitech acquisition in
Brazil
First MII project in LATAM
20 MII Certified Resources
SAP Preferred Partner for LME
MII Award (PEMEX)
MII Award (Petrobras)
MII Excellence Center (Brazil)
40 MII Certified Resources
1st MII 12.0 implementation
in LATAM
MII Award (Fosfertil)
MII Award (CINTAC)
75 MII Certified Resources
USIMINAS Video Wall
MII Award (USIMINAS)
MII Global Template
(Ireland/Dubai)
MII Global Template
(Ireland/USA)
MII Project (Brazil)
MII Project (Brazil)
MII Project (Brazil)
MII Project (Brazil) MII Project
(USA)
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Global Coverage And Delivery Excellence Focus
Neoris Experience
Neoris is a leader in MII implementation projects with plenty of MII experienced consultants.
Neoris established a global MII practice to support all implementations ensuring quality and best practices.
Globally, Neoris has the largest number of MII projects and credentials of any system integrator.
Neoris Methodology and Framework
Neoris methodology uses a robust framework for the integration of advanced systems which allows for reutilization of components designed specifically for each industry.
As a result, the total cost of ownership (TCO) of the solutions offered by Neoris is dramatically reduced for our clients.
USA
Colombia
Chile
Argentina
Brazil
Mexico
Spain
1 Global MII Practice
5 Local MII Practices
4 Delivery Teams
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Index
SAP MII Solution Overview
Welcome And Introduction
About Neoris
SAP MII Solution Overview
Sauder Woodworking MII Implementation
Closing and Q&A
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What Is SAP MII?
MII enables adaptive manufacturing by synchronizing manufacturing operations with the enterprise to deliver “a single version of the truth” and drive manufacturing excellence.
Manufacturing Integration: a single, standards-compliant application that integrates ERP connectivity with real-time plant floor applications whether in a single plant, or across multiple plants, business units and regions.
Manufacturing Intelligence: a real-time analytics engine that aggregates and delivers a visualization of events, alerts, KPIs, and decision support through role-based dashboards.
MII
Adaptive Manufacturing
Manufacturing Operations ERP
Manufacturing Intelligence
Manufacturing Integration
Manufacturing Synchronization
Data Integration
Work Process Management
UI Simplification
Performance Management
Dashboards
Scorecards
Analytics
Lean/Six Sigma
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How Do You Exchange Plant And ERP Data?
Data errors
Repetitious, manual processes
Delayed reporting
Business process delays
Poor information visibility
Reactive performance management
Materials Maint
Production Planning
Quality Ware house
Production
Custom systems
Databases
SCADA
Legacy-System
SPS
LIMS
Excel
HMI
DCS
Historians
ERP
Plant Maint
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Typical Non-Integrated Environment Manual processes and integration
MAKE
Execution
Inspection/ Equipment Testing Weigh Scales
SCADA / DCS LIMS / MES
HMI
Plant Data Collection RFID Sensors
PLC
Mobile Device Integration Environmental
Building Mgmt
Plant Historian
Distributor / Customers
Suppliers
Contract Manufacturer
LOB
Devices
PLAN MAKE DELIVER
Global Coordination
ERP
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SAP MII
MII extracts data from ERP and provides real-time
visibility and distribution to shop floor systems of:
MII’s ability to perform transaction execution into ERP also enables automated, plant-
level creation of:
Manufacturing Integration and Intelligence
Composition Environment Data Services
Visualization / Simplification / Alerting
Business Logic Services
Quality Engine
KPIs / Metrics
PLAN MAKE DELIVER
MAKE
ERP
Inspection/
Equipment Testing
Weigh Scales
SCADA / DCS
LIMS / MES
HMI
Plant Data
Collection RFID Sensors
PLC
Mobile Device
Integration Environmental
Building Mgmt
Plant Historian
•Planned Orders
•Bills of Material
•Production/Process Orders
•Material Inventory Levels
•Inspection Lots Data
•Master Recipes
•Material Details
•Batch Details
•Resources Locations
•Functional Locations
•Maintenance Work Order
•Maint. Notification details
•Material and Order Costs
•Production Confirmations
•Process Messages
•Material Receipts
•Material Consumptions
•Material Transfers
•Inspection results recording
•Quality Notifications
•Batch Characteristic recording
•Work Orders/results
recording
•Maintenance Notifications
Delivers information and process integration
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Competitive Summaries
Competitive Products
Need data replication – creating multiple copies of the same data in their data structure
Have longer time to benefit
Utilize other technologies / products for SAP ERP integration
May lack transactional capability (often read only)
Difficulty in delivering SAP integration – few references, most with minimal implementations
SAP MII Benefits
Provides integration and intelligence in one product
Leverages existing investments - minimizes data replication
Integrates quickly to SAP Business Suite using pre-built templates
The most intimate manufacturing technology to SAP Business Suite
Applications are developed and deployed very quickly – time to benefit in weeks
Strong partner ecosystem
Global support from SAP
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User Interface Simplification Production orders, bills of materials, goods movements, etc.
Simplified user interfaces that allow shop floor workers to interact with ERP data (such as production orders, bills of materials, material details, maintenance notifications) in the context of their local work processes.
Production Confirmations
Material Receipts
Material Consumptions
Material Transfers
Inspection results recording
Quality Notifications
Work Orders/results recording
Maintenance Notifications
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Manufacturing Dashboards
Dashboard: a reporting tool that presents manufacturing key indicators on a single screen, which includes measurements, metrics, and scorecards.
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Overall Equipment Effectiveness (OEE)
OEE is a hierarchy of metrics which focuses on how effectively a manufacturing operation is utilized.
OEE - waterfall chart of performance losses for a
particular machine
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Real-Time Asset Information
Real-time information from shop floor equipments available on an MII dashboard.
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Video Wall – Supply Chain Visibility
Provide an integrated view of information from the various processes and puts together employees of various processes in a single room.
The integrated operations center has a Video Wall screen with approximately 43 feet wide by 6 feet high.
* Neoris YouTube channel: http://www.youtube.com/watch?v=xmRYPE1A_Oo
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Quality Monitoring
SPC data analysis takes advantage of the MII business logic services and associated Data Connectors. MII gathers data from existing data sources and streams the resulting query into an SPC calculation engine.
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Plant Maintenance Simplification Simplify the process and operation for users in the plant maintenance space
View and search material, equipment, work orders
Create, display, change maintenance work orders
Create notifications
Time recording
Material consumption
Work order code maintenance
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Integration With Shop-Floor Equipments Scales, barcode reader, printers, robots, etc.
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Mobile Applications
Watch Portal is a mobile application that allows the end-user to create its own dashboards, favorites list, alarm level settings and alarm information distribution lists (including SMS messages)
Accesses shop floor information in real time from any mobile device via a secure web browser connection
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Index
Sauder Woodworking MII Implementation
Welcome And Introduction
About Neoris
SAP MII Solution Overview
Sauder Woodworking MII Implementation
Closing and Q&A
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Sauder Woodworking
North America's largest maker of ready-to-assemble furniture (RTA)
Started in 1934 by Erie Sauder
Privately held, second and third generation, family-run business
Headquartered in Archbold, Ohio
$540 million in sales
Approx 2,300 employees
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Sauder’s SAP Implementations
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Sauder MII Journey
Began to investigate the SAP PP module in 2005
SAP PP module investigation put on hold
– Lean initiatives first!
Don’t automate existing processes
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Sauder MII Journey
Sauder 2006 IT Highlights - IT Success – Change is necessary!
We can’t just maintain the status quo
– We must move from the mindset of “upkeep” to “innovate”
– We must find ways to become faster and more responsive
– Our solutions must be tied to business strategies
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Sauder MII Journey
Sauder IT Key Challenges – Increase visibility on execution processes
– Improve manufacturing flow and efficiency by following a strategic direction for lean manufacturing
– Simplify work order reporting process
– Manage increased IT requests from shop floor
– Find manufacturing shop floor systems that are lean enablers
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Sauder MII Journey
Why SAP MII? – Ability to deliver a manufacturing performance application
in weeks
– Flexibility to change how shop floor operators interact with specific processes
– Built-in integration of multiple real-time shop floor and business system data sources
– Value of extending the SAP ERP application without incremental training of shop floor personnel
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Sauder MII/SAP History
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Drawer Focused Factory
2006 – Legacy Systems
Sauder’s “Pilot” Project
Pilot Project Goals
– Increased visibility
– Simplify work order reporting process
– Rapid delivery
– Ensure success
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Drawer Focused Factory
Pilot Project Scope
– Team Leader Dashboard
Provide overall view of focused factory
– Operator Dashboard
Replace IOV (Integrated Operator View)
Simplify work order reporting
– Connectivity to multiple data sources
.txt and .pdf file access
Avantis (SQL)
VPE (Oracle)
Legacy Manufacturing Systems (DB2 400)
PLC
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IOV was a VB solution provided by our APS/MES solution provider at the time.
The same application was used at all work centers
Employee and work center badges were required to complete transactions
Sixteen actions were required to report the production of one pallet of product
Too much time was being spent by operators standing at a PC entering transactions
Drawer Focused Factory
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IOV Process
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Drawer Focused Factory
Delivered implementation in 9 weeks within budget
Minimized development and testing costs with rapid delivery from implementation partner
Reduced interface and maintenance support with connectivity to multiple data sources by one application
This project provided a good example/pilot of what MII can do to accelerate the lean journey!
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OEM Focused Factory (2007) – SAP System Sauder IT staff began to develop using the MII tool.
Sauder had the opportunity for new OEM business that didn’t use standard raw materials etc., so the decision was made to implement SAP PP module for the business venture.
MII was used as the shop floor interface.
First Sauder implementation with MII connecting to SAP system. Operators posted Production Order Confirmations and Inventory Transactions.
Molding and Edgebanding Focused Factories (2008 and 2009) – Legacy System Internal Sauder Resources responsible for MII development
Moved into rapid development processes, reusable components and standard designs emphasized
Final Assembly Focused Factory (2010) – SAP System Sauder implemented SCM 7.01 (PPDS, SNP, SCN)
Focused Factory Implementations
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MII Upgrade Project
2010 – MII Upgrade (11.5 > 12.1)
Began our partnership with Neoris
Two Neoris FTEs on-site for four weeks
SAP MII best practices were followed
Over 900 MII files were reviewed
Approximately 350 files required modification
Five main MII applications for different shop floor areas were converted
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MII Upgrade Project
Shop Floor users were heavily involved in testing
Area Leaders/Group Leaders were trained as front-line support on the shop floor
Neoris provided on-site training related to MII 12.1 after go-live to Sauder development resources
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MII Upgrade Project
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Sauder MII Landscape
Three tiers (All virtual machines)
– DEV
– QAS
– Two PRD servers
Manual load balancing
Shop floor PCs have a primary shortcut to one of the PRD servers and a backup shortcut to the other PRD server
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Factory database: SQL database which replicates selected SAP data to improve performance
Production order and Material Master changes are pushed to the SQL database
MII accesses SQL for most-needed information instead of constantly requesting data from SAP
Sauder MII Landscape
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2012 – SAP System
Ten-month project duration
All previous MII solutions were replaced with a single solution for all shop floor processes
Neoris partnership: 2 FTEs from Neoris as part of project
On site and remote support
Provided best practices
Provided shop floor operators with the information they need to do their jobs
What production order should I be working on?
What information do I need to complete the order?
SAP Manufacturing Project
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Change Status/Crew Size/Shift
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Confirm Good/Reject Quantities
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Display Preparation Documents
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Display Transaction History
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Order Operation Dependencies
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Reprint Load Tag or Load Label
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Confirm Standard Load Quantity
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Verify Components / Goods Issue
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Sauder’s Journey Continues
Recently delivered MII Transactional Marquees to shopfloor
– Provides information for the current order and current shift
– Based on transactions posted by the MII shop floor user interface
– Consistent format for all shop floor areas
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MII Transactional Marquee
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Sauder’s Journey Continues
Beginning to look into mobile capabilities
– Operator real time scrap reporting on our lamination lines
Large lines, location of PCs not sufficient
– Ability to provide mobile devices to transact inventory transactions wherever needed
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Financial and Strategic Benefits
Improved execution processes on the factory shop floor
Improved and streamlined connectivity using one application to integrate multiple data sources
Achieved fast adoption and improved ease of use of new manufacturing dashboards
Complemented the lean journey at Sauder
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Operational Benefits
SAP MII is enabling throughput to be increased, while operator interaction (non-value-added activities) has been reduced by 85%
SAP MII has greatly streamlined the work order reporting process
Manufacturing dashboards have been simplified, providing a common and consistent solution
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Operational Benefits
Dramatic reduction for the need for training shop-floor operators as the enterprise application landscape evolved
SAP MII has given Sauder increased visibility into production line processes on the factory floor
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Index
Closing and Q&A
Welcome And Introduction
About Neoris
SAP MII Solution Overview
Sauder Woodworking MII Implementation
Closing and Q&A
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On-Line References
Neoris' Corporate Video: http://www.youtube.com/watch?v=misxKCHFcq4
Neoris’ MII Whitepaper: http://www.neoris.com/files/neoris_mii_onepager_en.pdf
Neoris' 3D Digital Factory at SAPPHIRE 2012: http://www.youtube.com/watch?v=nM6HqctxV84
Neoris' Video Wall at SAPPHIRE 2009: http://www.youtube.com/watch?v=k9NJ7c71nls
Neoris' Video Wall at SAPPHIRE 2010: http://www.youtube.com/watch?v=Rz0cN5TJozc
Neoris' Video Wall (English Subtitles): http://www.youtube.com/watch?v=hWAEjIQaYJQ
Usiminas Steel - Video Wall: http://www.youtube.com/watch?v=xmRYPE1A_Oo
Neoris Article: “SAP MII - Visibility in Practice”: http://www.neoris.com/files/SAP_MII_Whitepaper_EN.pdf
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Could MII Be Viable For Your Organization?
OPTION 1: Discovery Call (1 hour, No charge for professional time)
A Neoris Manufacturing specialist will:
Listen to your key issues and how they affect manufacturing, scheduling and your supply chain
Introduce SAP MII and discuss case histories of how other companies have driven business process improvements, both locally and globally
Discuss how SAP MII may be used in your organization’s quest for the Perfect Plant
Lay the groundwork for a discovery workshop that will fully define an initial business benefit case
OPTION 2: A Discovery Workshop (1 to 2 days, No charge for professional time)
A typical Discovery Workshop covers:
SAP MII overview with usage examples and references
A visit to the plant floor to understand the current issue
Key issue discussion with stakeholders to identify potential KPIs and SAP ‘touch points’
Review of the KPI’s value, financial impact and time-to-benefit
Scoping of a statement of work
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Q & A
Peter Molina Director Tel: (305) 728-6045 Cell: (847) 942-9226 peter.molina@neoris.com
Tom Taylor Director Tel: (305) 728-6126 Cell: (908) 578-4560 tom.taylor@neoris.com