SAP’s MII Real WorldManufacturing Applications

Topics

Introduction to MII/Seeit Solutions

Real World MII ApplicationsEfficiency

MII OEEQuality

MII Quality & SPCUtilities – Energy MgmtShop Floor Labor Tracking

MII Labor TrackingMobile Worker

MII HandheldHAACP

Why Seeit Solutions as Your Partner?

Discussion and Questions

Introductions: SeeIT Solutions

SeeIT Solutions100% focused on SAP Plant Floor to ERP solutions

From I/O & PLC’s to SAP ERP ModulesSAP Authorized Services PartnerSAP MII FET certifiedExperience with Lighthammer (now MII) since 2001 with manyinstallationsCustomers include PepsiCo., Anheuser Busch, MillerCoors, Sargento,Gallo, Nestle, Lockheed Martin, Molex, Metalcraft, Whirlpool,Certainteed, Kraft FoodsFocused on solutions that track efficiency, improve quality, and orderexecution while reducing cost and riskSeeIT MII Factory Event DatabaseIntegration experience with Plant Floor Solutions: Rockwell, Siemens,GE Fanuc, Infinity QS, Maximo, Kronos Time and Attendance,Informance/OEE, Hand held/mobile deployments

Current Status…

Excel and Paper Analysis

SAP

MII

EMO

ERP/MRP

ManufacturingIntelligence

ManufacturingIntegration

Automated ERP transactions

Automated processes

ERP visibility

Composite metrics

Service enablement

Operational Excellence

TPM/Lean Manufacturing

Continuous Improvement

Six Sigma

MII = Manufacturing Integration and Intelligence

Real World Applications

Beverage Manufacturer

Global Electronics Manufacturer

Defense Contractor – Missile Manufacturer

Food Processor

Metal Fabrication & Lawn Mower Manufacturer

Building Products Manufacturer

Real World Application - Beverage Manufacturer

Business DriversLine Efficiency and Manufacturing Reporting/Automatic Production

Confirmations

ResultsTight SAP ERP integration using MIIEfficiency by Plant, Line, Asset, Product, …Lot Receiving User Interface

Simplified GUIMaterial Flow and Material Efficiency ReportingFinished Goods Confirmation Reporting

Automatic Production Confirmations into SAP ERP

Screens

Real World Applications

Beverage Manufacturer

Global Electronics Manufacturer

Defense Contractor – Missile Manufacturer

Food Processor

Metal Fabrication & Lawn Mower Manufacturer

Building Products Manufacturer

Molex – Global Electronics Manufacturer

MII chosen as global standard for Shopfloor and MES capability

Utilize a standard and simple interface for all requirementsbetween shopfloor and SAP ERP

Single User interface for manufacturing employees (confirmations,schedule, etc.)Kronos MII Interface (Seeit Developed)

Provide local survivability in cases where SAP is down globally

Currently using MII forShopfloor SAP interactions (confirmations, schedule, etc)Productivity and Efficiency monitoring including Machine OEEHandheld RF interface to SAPInterface SAP to Kronos for labor and work order activitiesOverhead Scoreboard Displays in Plant

Molex – Shopfloor Information System Objectives

Allow for SAP Production Order Confirmations utilizing actual machinedata (quantities, scrap, downtime, etc.)

Enable the ability to gather machine events details for production anddowntime occurrences linked by production order, shift, date, operator, etc.

Increased Efficiency and Productivity by providing visual feedback tooperators and managers about current operations based on real time actualdata

Increase visibility to Shopfloor landscape utilizing actual machine data(runtimes, production order numbers, production rates, actual vs. plan, etc.)

Present a view to machine and tool planning for use on the Shopfloor

Allow for analysis of machine downtime

Data needed to be captured by machine centre, tool, operator, shift, anddate

Plant Overview

Department Overview

Machine Overview

Machine Downtime Details

Post Production Confirmation to SAP

Post Machine Downtime and Reasons to SAP

Production Order Details

Production Plan Overview - Daily

Production Plan Overview - Weekly

Shift Production Report

Report – Top 10 Stopped Machines

Report – Machine Top 10 Downtime Reasons

Report – Downtime Events over 15 Minutes

Handheld - Main Menu

Handheld – Post Production Confirmation to SAP

Handheld – Downtime Confirmation to SAP

Real World Applications

Beverage Manufacturer

Global Electronics Manufacturer

Defense Contractor – Missile Manufacturer

Food Processor

Metal Fabrication & Lawn Mower Manufacturer

Building Products Manufacturer

Lockheed Martin – Defense/Aerospace Manufacturer

MII chosen as Shopfloor SPC System for MFC

Utilize a standard and simple interface for machine operators andquality professionals in the plant

Single User interface for shopfloor employees (confirmations,inspections, etc.)QM interface & CMM interface

Provide local survivability in cases where SAP is down globally

Currently using MII forShopfloor SAP interactions (inspections, qc data, etc)CMM InterfaceSAP QM Interface

Inspection Results Acceptance and Posting to SAP

Production Order Entry

Characteristic Selection

SPC Display

Result Comment Entry

Characteristic Data Details

Real World Applications

Beverage Manufacturer

Global Electronics Manufacturer

Defense Contractor – Missile Manufacturer

Building Products Manufacturer

Metal Fabrication & Lawn Mower Manufacturer

Food Processor

Certainteed Building Products

Shop floor reporting/information system

Quality focused project—Lost production reporting

Production reporting: Safety, VOC, Inventory, Production

Targets and actual vs. targets recorded

Historian Interface (Real-time and Historical data)

Factory Event Interface

4000+ users over many plants

Building Products Company Example

Real World Applications

Beverage Manufacturer

Global Electronics Manufacturer

Defense Contractor – Missile Manufacturer

Building Products Manufacturer

Food Processor

Metal Fabrication & Lawn Mower Manufacturer

Food & Beverage Processing

Shop floor information system

Tracking asset utilization-OEE

Historian Interface (Real-time and Historical data)

SeeIT Factory Event Database (Downtime and Scrap)

Scoreboard/Overhead Factory Displays

Tight SAP integration using MII

100’s of assets per plant-many plants back to central ERP

Packaging Operator Examples

Packaging Performance Details

Packaging Machine Details

Packaging Quality Dashboard

Overhead Scoreboard Display Example

From a Food ProcessingCompany

Machine Status

Current DowntimeInformation

Production rates

Waste/Quality Panel

Production Metrics

“Tip of the Day” Scroll

Food Processor Lunchroom Scoreboard

Food Processor ManagementDashboard

SPC Net Weight Dashboard

Environmental

Boilers

HVACAir Comp.Chillers Electric Power

Gas

Maintenance

Management

Asset

Management

Energy

Management

This place givesme a headache

LightingControl

Digital Dashboards

Real World Applications

Beverage Manufacturer

Global Electronics Manufacturer

Defense Contractor – Missile Manufacturer

Building Products Manufacturer

Food Processor

Metal Fabrication & Lawn Mower Manufacturer

Metalcraft—Industrial Lawn Mowers/Parts

Shop floor job tracking

Operator User Interface for labor/job tracking

Recording steps, actual vs. planned

Automatic Updates to ERP for actual by product, crew, …

800+ Users, multi-plant

Interfaces

SAP HR, PP, MM & IM modules

3rd Party Dynamic Nesting softwarePassing Work Order dataReceipt of transactional dataAutomatic Goods Movement (Issue) of material

3rd Party Label Printing software

Warranty Tracking database (internal)

Features

Real-time Inventory & Work Order/Operation updatesinto SAP

Time clock collection

Crew clocking management/collection

SAP database validationPP - Work order dataHR - Employee & Work Schedule master filesMM - Material master

Main Operator Menu

Operator Clock In

Secure scanning ofemployee badges for ALLtransactions

Time Clock functionality

Job On/Off

Work order data scanned fromshop packet

Reporting of good & scrap qtys

Request to print a travel ticket

Supervisor Functionality

Employee data displayed based on Supervisor/Employeerole assignment in SAP HR

Ability to review data transacted by each employeeMake adjustments to quantities reportedMake adjustments to transaction times

Audit tracking of changes

Traffic light feature indicating errors

Rounding rules based on employee Work Schedule inSAP HR

Entry of employee Absences

Employee Time Clock data & absences passed to SAPHR CATS

Mass employee approval of transactions into SAP HR, PP& IM

Labor Efficiency dashboard

Supervisor Panel

Supervisor Screens

Discrepanciesindicated byradio lights

Time &Attendancereview andAbsence entry

Labor Efficiency Dashboard

Multiple reportingselections

Date rangesBy WO, Shift, WorkCenter, Cost Center,Employee

Closure of Examples

Introduction to MII/Seeit Solutions

Real World MII ApplicationsEfficiency

MII OEEQuality

MII QualityUtilitiesShop Floor Labor Tracking

MII Labor TrackingMobile WorkerHAACP

Discussion and Questions

Experience with product-7+ years

Experience with MII across many diverse applications

SAP Authorized Services Partner

MII Field Enabled Training (FET) certification

Getting Started Process for MII

MII Readiness Survey

Pathfinder – Justify/Sell Your Project

MII Configured Solutions

Understand Shopfloor Information flow (PLC to ERP)

US Based development team

Why Choose SeeIT Solutions as Your MII Partner?

Seeit Solutions MI Applications?Partial listing of some of Manufacturing Intelligence (MI) application

templates and interfaces that Seeit has developed:

• mi•Performance Metrics™ - configurable performance metrics enabled by a Performance EventDatabase

• mi•Workforce™ - directional interface between Kronos Workforce Timekeeper & Activities to SAPPP/PP-PI, & HR

• mi•Mobile™ - use mobile devices to transact to and from SAP ERP and receive real-time reports

• mi•Touchscreen™ - a shop-floor application designed by the user with direct updates and interactionwith SAP ERP

• mi•Labor Tracker™ - an application that provides transactions to update your SAP HR and CATS

• mi•SPC Shopfloor™ - shop-floor SPC application presenting real-time Quality and Attribute datacollection & charting with updates to SAP QM and PP/PP-PI

• mi•Intelligent Historian Connect™ - interface data to SAP ERP from your Process Historian

• mi•Production Scheduling Board™ - a shop-floor scheduling updated from SAP planned ordersor APO

• mi•Scoreboards™ - an application designed to drive large overhead monitors presenting KPIs fromSAP or other plant based systems

Leveraging our 20 Years Experience integrating ERP to the Plant

Questions…

Contact Information

Kevin Bader

Partner

SeeITSolutions LLC

(262) 378-4699(847) 612-8497

kevin.bader@seeitmii.com

www.seeitmii.com

TC

Brian Kuchinski

Sr. Program Manager

SeeITSolutions LLC

(847) 483-8703(847) 456-7534

www.seeitmii.com

TC

Data Collection from I/O to SAP ERP

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