Core Manufacturing Detailed

8/11/2019 Core Manufacturing Detailed

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Core Manufacturing

Arne MantheySAP AG

06/2010



© SAP 2007 /

ERP

SFAC

MES

Shop Floor

Automation

Monolith ic Systems

MOM

Shop Floor

Automation

ERP

Distributed Functions

System Borders blur…



Plant Maintenance

Equipment Qualification

Maintenance Orders Time Tickets

Component -

Consumption

Work Assignment

Tools

Plant Maintenance

Equipment Qualification

Maintenance Orders Time Tickets

Component -

Consumption

Work Assignment

Tools

Production Planning

Production Orders /

Process Orders (S88) Operations / Phases

Time Tickets

Material Consumptions

PI Sheet / Electronic

Work Instructions

Production Planning

Production Orders /

Process Orders (S88) Operations / Phases

Time Tickets

Material Consumptions


Work Instructions

Warehouse Mgmt.

Production Supply

Transportation Orders

Warehouse Mgmt.

Production Supply

Transportation Orders

© SAP 2007 /

Quality Mgmt. Inspection Tasks

Inspection Lots

Sample Management

Usage Decision

Test Results -Recording

Quality Mgmt. Inspection Tasks

Inspection Lots

Sample Management

Usage Decision

Test Results -Recording

SAP ERP Touchpoint Processes with

Manufacturing

E R P

E R P

WMWM

WMWM PMPM

PMPM QMQM

QMQMPP /PP /

PPPP--PIPI

PP /PP /

PPPP--PIPI

APO APO

PP/DSPP/DS

APO APO

PP/DSPP/DS

Human Resources Qualification Records

Human Resources Qualification Records

Materials Mgmt. Inventory Control

Goods Movement

Batch Information

Material -Reservations

Material -Characteristics

Purchasing

Tools

Materials Mgmt. Inventory Control

Goods Movement

Batch Information

Material -Reservations

Material -Characteristics

Purchasing

Tools

MMMM

MMMMFIFI COCO HRHR

HRHR



© SAP 2007 /

Manufacturing Levels and Landscape

FIFI COCO

E R P / S C

M

E R P / S C

M

M O M

M O M

S F A C

S F A C

HRHR

HRHR WMWM

WMWM MMMM

MMMM PMPM

PMPM QMQM

QMQM APO APO

PP/DSPP/DS

APO APO

PP/DSPP/DS

~1s

~8h

PI Sheet /

Electronic

Work Instructions

PP /PP /

PPPP--PIPI

PP /PP /

PPPP--PIPI

SAP MII

SAP Templates

& Partner Content

Separate

Manufacturing

Systems(MES, LIMS, Maintenance)

Visipri se / SAP ME,

Werum, … )

Separate

Manufacturing



Werum, … )

DCS / PCS

DCS / PCS

OPC

Devices

Devices

Industrial Bus

…Weigh Scales Actors Meters

Data Historian

Data HistorianSCADA / HMI

SCADA / HMI

Enterprise Services BAPI / RFCProcessProcess

MessagesMessages

FunctionFunction

CallCallIDOCIDOC

PIPI--PCSPCS

ControlControl

RecipesRecipes

PCo SAP ODA



SAP Solutions for Manufacturing Execution

low-automation,

low-complexity,

central

high-automation,

high-complexity,

stand-alone

Process

DiscreteME

( )

© SAP 2008 /

MII Content Shop floor transactions

Worker UI

MII Content

Shop floor transactions Worker UI

ERP/PP Electronic Work

Instructions

XSteps

OPC

ERP/PP-PI PI-Sheets

XSteps OPC

http://images.google.de/imgres?imgurl=http://www.wonderware.it/about_us/Newsletter/2005/Feb05_file/NewLogo_Wonderware.gif&imgrefurl=http://www.wonderware.it/about_us/Newsletter/2005/Feb05_file/SAMFeb05.htm&h=142&w=307&sz=6&hl=en&start=7&tbnid=ZsJ9cBjdSzFJXM:&tbnh=54&tbnw=117&prev=/images?q=wonderware+logo&gbv=2&hl=en



© SAP 2007 /


Using ERP Manufacturing only

FIFI COCO

E R P / S C M

E R P / S C M

S F A C

S F A C

HRHR

HRHR WMWM

WMWM MMMM

MMMM PMPM

PMPM QMQM

QMQM APO APO

PP/DSPP/DS

APO APO

PP/DSPP/DS

DCS / PCS

DCS / PCS

~1s

OPC

SAP ODA

Devices

Devices

PIPI--PCSPCS

Industrial Bus

PI Sheet /

Electronic

Work Instructions

PP /PP /

PPPP--PIPI

PP /PP /

PPPP--PIPI

A u t o m . P r o c e s s

M e s s a g e s


Synchronous Data Transfer Asynchronous Data Transfer

ProcessProcess

MessagesMessages

ControlControl

RecipesRecipes

FunctionFunction

CallCall

M O M

M O M

~8h

Separate

Manufacturing



Werum, … )

Separate

Manufacturing



Werum, … )

Data Historian

Data HistorianSCADA / HMI

SCADA / HMI

MII


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PP / PP-PI

FIFI COCO E R P / S C M

E R P / S C M

S

F A C

S

F A C

HRHRHRHR WMWMWMWM MMMMMMMM PMPMPMPM QMQMQMQM APO APOPP/DSPP/DS APO APOPP/DSPP/DS

DCS / PCSDCS / PCS

OPC

SAP ODA

DevicesDevices

PIPI--PCSPCS

Industrial Bus

PI Sheet /Electronic

Work Instructions

PP /PP /

PPPP--PIPI

PP /PP /

PPPP--PIPI

A u t o m . P r o c

e s s

M e s s a g e s



ProcessProcess

MessagesMessages

ControlControl

RecipesRecipes

FunctionFunction

CallCall

M O M

M O M

Third PartySystems(MES, LIMS, Maintenance)

Visipri se, Werum, …

Third PartySystems(MES, LIMS, Maintenance)

Visipri se, Werum, …

Data HistorianData HistorianSCADA / HMISCADA / HMI

Transaction DataMaster Data

XStepRepository Routing / Recipe Production / Process Order

BOMXSteps

Header

Operations

/ Phases

BOMXSteps

Header

Operations

/ Phases

Standard

XSteps



PP /PP /

PPPP--PIPI

PP /PP /

PPPP--PIPI

© SAP 2007 /

PP / PP-PI:

XSteps, Master and Transaction Data

Transaction DataMaster Data

Order

Work Centers

/ Resources

Materials

(MM)

XStep

Repository

Routing / Recipe

+

+

+

BOMXSteps

Header

Operations

/ Phases

+

++

+

+

BOMXSteps

Header

Operations

/ Phases

+

+

+

+

+

Control Recipes

Electronic Work Instructions / PI Sheets

Documents

(Cross)

Equipments

(PM)

P P



Header with order information

Containers for Operations / Phases(can be collapsed)

Instruction containers for convenient

structuring

Long text elements are on the left side

Short text and input elements are on the rightside

Tables stretch over the whole width

Repeated data input (extendable with new lines)

Grouped elements with similar structure

(e.g. check lists, generated material lists, …)

Scrollable

Input history can be logged

Comments can be entered at any time

© SAP 2007 /

Features of the PI Sheet / Electronic Work

Instruction (I)

PI Sheet - Change

Process order : 000123456 Material Number 10001234 >>

Change -> Display Save Complete Print Create Comment

Phase 0010

Goods receipt

Weighing

Preparation:

• Enter production date

• Enter tare weight of pallet

• Enter average weight of pieces

Weighing

• Put bin on the weigh scale

• Get bin weight

• Check result and confirm (OK?)

Sign the goods receipt

Production Date 08.06.2006

Tare weight of bins [kg] 1.000

Avg. piece weight [mg] 200.0

Signature

Total of pieces 21000



Output of text instructions

In- and output of valuesDefault values, value validation

Tables

Calculations

Function calls

OPC data access(e.g. read measurement from device)

Digital signature (simple, multiple)

Automatic generation of order-related object(e.g. documents, components,…)

Event-triggered execution of commands and functions Automatic execution of functions (e.g. immediate check of material status)

Activation/deactivation of instructions based on conditions

Process messages

(Activity reporting, material consumption/production,…)

© SAP 2007 /

Features of the PI Sheet / Electronic Work

Instruction (II)

Tablet weighing



XStep Life Cycle (I)

SXS Repository Routing/Recipe Order

© SAP 2007 /

SXS Repository

XStep Section o f Routing

XStep Section of Produc tion Order

SXS with parameters

Generated elements

(3 material components

assigned to the order)

Parameter values related to a specific component

Automatic valuation

of parameters

Routing-specific parameter values



XStep Section of Product ion Order

Electronic Work Instruct ion (EWI)

XStep Life Cycle (II):

Order EWI/PI Sheet Process Message

© SAP 2007 /

Parameter values (Diameter Setup )

Line completed

PP_CONS Process Message

Material List in Production Order

Default value Deviation

Process message

books material

consumption



Release History

Release Business Function Solution Characteristic Details

R/3 4.6c -HTML-based PI Sheet instructions(Big fon ts, images,…)

HTML formatting (Big fonts, images,…)

Flexible usage of custom function modules New generic process instruction (Type 0)

Electronic Batch Record (EBR)

R/3 4.7 -

Adapt iveness by usage of commands

and events

Easy OPC integration SAP ODA

R/3 4.7

Ext. 2.0- XSteps – Easy to reuse building blocks

ERP 2005

EhP2LOG_PP_PI_EHM

Process Industry Enhancements:

XSteps (regulated environment)

EhP3

LOG_PP_XS_RTG_PO XSteps for Routing and PO (Discrete)

LOG_PP_PMA_PMC Misc. PI Sheet enhancements

General styleheet enhancements

Discarding PI Sheets from process order

Mandatory entries by setting in characteristic

Improved PARAMETER_CHANGED event

New PDF printing function

Standard XStep L ibrary Collection of Standard XSteps:

SDN ( Downloads Core Manufacturing)

EhP5

(planned)

LOG_PP_PI_PMA_01 Archiving of PI Sheets and EWI

LOG_PP_XS_01 XStep enhancements for global izat ion Cross-plant repository

Language dependency



Summary

PI Sheets / Electronic Work Instruct ions:

‚One-stop shop‘ for the worker to access and provide all ERP-relatedinformation. No need to run multiple transactions.

Flexibility and speed by dynamic and event-triggered instructions

Control of the material and information flow between ERP and production

systems (OPC)

XSteps: XSteps are easy to create and maintain. Much of the day-to-day work can be

done by functional departments. The IT department can concentrate on more

complex areas.

The repeated use of standard building blocks (SXS) reduces the maintenance

effort for the master data definitionInformation and XStep examples are available on:

BPX Community for Manufacturing

XStep Café



Thank you!



Title

MDA & OPC



Interfaces with factory floor systems:

PI-PCS vs. OPC

PI-PCS Interface SAP OPC Data Access Message based

Targets fully automated processes

without user interaction

Asynchronous

Subscription

Vendors have to implementinterface;

Certification of solutions

Manual or semiautomatedprocesses with user interaction

(e.g. PI-sheet)

Synchronous

Industry standard is used;

no certification necessary

Generic

(any OPC DA Server)

Both interfaces complement each other !



What is OPC?

” OPC is open connectivity via open standards”Source: OPC Foundation

Non-proprietary Industry-Standard

Non-profit Organization

Nearly 400 Members

www.opcfoundation.org

OPC St d d ff d b SAP ERP



OPC Standards offered by SAP ERP

OPC Data Access (OPC DA)

OPC Events & Alarms (OPC EA)

OPC for Batch

OPC DX

OPC Data Historian

OPC XML

Security

OPC I t f i SAP ERP



OPC Interface in SAP ERP

Manufacturing Operations

COM

SAP ERP: PP-PI

PI Sheet / EWI

SAP OPC: ODA Data Access OAE Alarms & Events

Local PC

SAP ODA Connector

(OPC Client)

OPC Server

RFC

Field

Local PC

SAP ODA Connector

(OPC Client)

OPC Server

R-01

Field

COM

AutomaticProcess

Messages

Download the SAP ODA Connector:

http://service.sap.com/manufacturing Downloads SAP OPC Data Access

Titl



Title

EhP2:Enh. for Regulated

Industries

U f St d d XSt i R l t d



Usage of Standard XSteps in a Regulated

Environment

Standard XSteps as Building Blocks for PI Sheets require additional features

(regulated environment):

Main features:

Approval procedure for SXS versions using digital signatures

Where-used list for SXS

XML export and import of folders, SXS and SXS versions

„Nice to have“:

Checksum test during XML import

Automatic numbering of SXS version

Automatic calculation of the valid to-date for released SXS version

Setup: Customizing [CMX21]

A l t t h f SXS i



Approval status scheme for SXS versions

A l t t h f SXS i



Approval status scheme for SXS versions

Wh d Li t f St d d XSt



Where-used List for Standard XSteps

Title



© SAP 2007 /

Title

EhP3:Misc. Enhancements

Overview



Overview

Detail Functions

General styleheet enhancements

Discarding PI Sheets from process order

Mandatory entries by setting in characteristic

Improved PARAMETER_CHANGED event New PDF printing function

Customizing:

For all functions except discarding PI Sheets from process order

SPRO PP-PI Process Management Control Recipes Activate

Enhancements for PI Sheet

New Features and Functions



New Features and Functions

Set fields mandatory with the

help of characteristics (flag

‚Entry Required‘ set )

Show comment icon in table cells

Enhanced New SAP Style Sheet



Enhanced New SAP Style Sheet

LED Green: Signature completed

LED Yellow: Signature in progress

with more than one signer

LED Grey: Signature present, not

started yet

No LED: No Signature present





started yet






started yet


Icon Deactivated: Phase contains

deactivated elements

Icon Locked: Phase contains

locked elements




locked elements




locked elements

Icon for Signatures already done:

There are signatures present

Icon for Deviations: Deviations

occurred in the phase

Icon for Comments: Comments

were created for the phase













Easy to Adopt New Monitoring Transactions



Easy to Adopt – New Monitoring Transactions

New transactions for

Control Recipe Monitor (CO53XT)

Process Message Monitor (CO54XT)

Work List for PI Sheets/Work Instructions (CO60 & CO60XT)

Using configurable ALV_GRID_XT:

Adding additional columns modification-free (via BAdI implementation and

customer-defined append structure)

PDF Print Function



PDF Print Function

Title



SXS Library: Facts

Purpose

Collection of best-practice building blocks

Speed-up of implementation

Required Functionality Release

Usage of XStep-based PI Sheets (PP-PI)Since R/3 4.70

Ext. 2.0

Importing of XStep folders Since ERP 2004

Usage of XSteps for production orders

(work instruction sheets)ERP 2005 EhP 3

Content of the SXS Library



Content of the SXS Library

Structure of the SXS Library



Structure of the SXS Library

Folders for different

categories of SXS

SXS

Every SXS has a separate

documentary instruction

(To be deleted for later use)

Sample instructions

demonstrate the usage

Simulation:

Displays a

preview ofthe SXS on

the right side

Example: Checklist



Example: Checklist

Show the usage of

SXS references

inside the SXS

repository

Show how parameters can be

used to control the behaviour of

an SXS reference (e.g. color)

Example: Material List



Example: Material List

SXS Repository

Process Order: XSteps

Process Order: Bill of Material

HTML code valuation

Generation

Scope

SXS reference

in process order

Simulated XSteps inprocess order

(including generation)

40 character

material short text

Example: CSS Adoption



Example: CSS Adoption

HTML long text with CSS

manipulation code

Change the background color

of the phase container

Change the background color

of the PI Sheet

How to get the SXS Library from SDN/BPX



How to get the SXS Library from SDN/BPX

Downloads Core Manufacturinghttps://www.sdn.sap.com/irj/sdn/bpx-manufacturing

Name of Download Item (ZIP file) Description

Flexible Building Blocks for Shop Floor Instruction Sheets -Basic Standard XStep Templates

Library of SXS wihich do not use any custom

characteristics or function modules

Flexible Building Blocks for Shop Floor Instruction Sheets - Advanced Standard XStep Templates

Library of SXS which use custom characteristics or function

modules. (To be created before importing the library)

Flexible Building Blocks for Shop Floor Instruction Sheets -Standard XStep Library

Both basic and advanced libraries

Title



© SAP 2007 /

g p

FIFI COCO

E R P / S C

M

E R P / S C

M

M O M

M O M

S F A C

S F A C

HRHRHRHR WMWMWMWM MMMMMMMM PMPMPMPM QMQMQMQM APO APO

PP/DSPP/DS

APO APO

PP/DSPP/DS

SCADA / HMISCADA / HMI

DCS / PCSDCS / PCS

~1s

~8h

OPC

SAP ODAPCo

DevicesDevices

PIPI--PCSPCS

Enterprise Services

Industrial Bus

PI Sheet /

Electronic

Work Instructions

PP /PP /

PPPP--PIPI

PP /PP /

PPPP--PIPI

A u t o m . P r o c e s s

M e s s a g e s


Mapping/S95

BAPI / RFC


SAP MII

ProcessProcess

MessagesMessages

ControlControl

RecipesRecipes

FunctionFunction

CallCall

XI/PI (opt .)XI/PI (opt .)

Visualization

Bus. Logic

D a t a S e r v i c e s

IDOCIDOC

SAP

Templates

& Partner

Content

Data HistorianData Historian

Separate

Manufacturing



Werum, … )

Separate

Manufacturing



Werum, … )

Connecting MII and PI Sheet /



© SAP 2007 /

g

Electronic Work Instructions

FIFI COCO

E R P / S

C M

E R P / S

C M

M

O M

M

O M

HRHRHRHR WMWMWMWM MMMMMMMM PMPMPMPM QMQMQMQM APO APO

PP/DSPP/DS

APO APO

PP/DSPP/DS


Work Instructions

PP /PP /

PPPP--PIPI

PP /PP /

PPPP--PIPI

BAPI / RFC


ProcessProcess

MessagesMessages

ControlControl

RecipesRecipes

FunctionFunction

CallCall

SAP MII

D a t a S e

r v i c e s

Visualization

Bus. Logic

HTTP request

Iframe (HTML)HTML content

HTTP

Data from MII

Visualization Applet

(Grid)

Query

Function Calls

Query

Display Template

Copyright 2007 SAP AG



py g

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