Microsoft Juergen_Denver_Manufacturing_Interoperability S95 14 Wettengl
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SAP Manufacturing & Interoperability Jürgen Wettengl ASM Manufacturing, SAP AG Agenda : SAP Manufacturing and Interoperability What is the situation today ? What are the problems ? What are the objectives ? How can SAP help ? What are the benefits? SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 2 Kitchen All In One SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 3 What is the situation today ? SFAC* * Shop Floor Automation and Control Systems SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 4 Manufacturing Business Processes ERP ERP ERP MES SFAC* What are the problems ? Disconnect Manufacturing Business Processes ERP ERP ERP Disconnect MES Disconnect SFAC* * Shop Floor Automation and Control Systems SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 5 SFAC* Why use standards like ANSI/S95? Plant Plant Systems Systems MM PP Legacy-System HMI kundeneigenes System Datenbanken PM PP/PI QM History SCADA LIMS SPS DCS SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 6 Tabellenkalkulation What are the objectives ? Cost Reduction per minimizing the number of interfaces, layers and data maintenance. Standardize the interfaces based on ANSI/ISA-95 B2MML messages. Logical integration between the ERP and the shop Floor systems to improve the data quality and the business processes. Improved usability and exception based proactive business process monitoring to control the route of the message transportation. Visualization and reporting of production relevant data from all involved levels from the shop floor to my SAP Business Suite. SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 7 Agenda : SAP Manufacturing and Interoperability What is the situation today ? What are the problems ? What are the objectives ? How can SAP help ? What are the benefits? SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 8 How can SAP help? Interoperability Scenarios – Best Practices Proactive Solution Monitoring SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 9 Example ANSI/ISA-95 Production Schedule Control Recipe Monitor ERP 1 xMII Send Control Recipe 2 Receive Control Recipe 3 Mapping to S95 production schedule 4 Send S95 production schedule messages to MES system 5 Receive, check and save S95 production schedule messages 6 Complete order data and save MES SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 10 Example ANSI/ISA-95 Production Schedule PP-PI-PCS Control Recipe Header xMII XI B2MML Production Schedule Production Schedule Request Product Segment Process Order Destination Material Produced Requirement Production Parameter(Process Order Related Process Order Detail BAPI: BAPI_PROCORD_GET_DETAIL Operation Detail Primary Resource Secondary Resource Produnction Resource Tool Componet Material Phase Detail Secondary Resource Produnction Resource Tool Material Consumed Process Instructions Process Segment-Operation Operation Material Consumed Requirement Material Consumed Requirement Property Equipment Requirement Equipment Property Personnel Requirement Phase Material Consumed Requirement Material Consumed Requirement Property Equipment Requirement Equipment Property Personnel Requirement Production Parameter(Process Instruction for Phase) SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 11 Example ANSI/ISA-95 Production Schedule SAP ERP PP-PI-PCS Control Recipe Header Invoke XMII Process Order (E.g. Send Control Destination Recipe) Process Order Detail BAPI: BAPI_PROCORD_GET_DETAIL Operation Detail Primary Resource Secondary Resource Produnction Resource Tool Componet Material Phase Detail Secondary Resource Produnction Resource Tool Material Consumed Process Instructions xMII XI B2MML Production Schedule Production Schedule Request Product Segment Material Produced Requirement Production Parameter(Process Order Related Process Segment-Operation Operation Material Consumed Requirement Material Consumed Requirement Property Equipment Requirement Equipment Property Personnel Requirement Phase Material Consumed Requirement Material Consumed Requirement Property Equipment Requirement Equipment Property Personnel Requirement Production Parameter(Process Instruction for Phase) SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 12 Example ANSI/ISA-95 Production Schedule SAP ERP SAP xMIIxMII PP-PI-PCS Control Recipe Header Invoke XMII Process Order (E.g. Send Control Destination Recipe) Process Order Detail BAPI: BAPI_PROCORD_GET_DETAIL XI Transform the Incoming request to a B2MML Standard XML Message Operation Detail Produnction Resource Tool Componet Material Phase Detail Secondary Resource Produnction Resource Tool Material Consumed Process Instructions Production Schedule Request Product Segment Material Produced Requirement Production Parameter(Process Order Related Process Segment-Operation Operation Primary Resource Secondary Resource B2MML Production Schedule Material Consumed Requirement Send theB2MML Message to Shop floor application Material Consumed Requirement Property Equipment Requirement Equipment Property Personnel Requirement Phase Material Consumed Requirement Material Consumed Requirement Property Equipment Requirement Equipment Property Personnel Requirement Production Parameter(Process Instruction for Phase) SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 13 Example ANSI/ISA-95 Production Schedule SAP ERP SAP xMIIxMII PP-PI-PCS Control Recipe Header Invoke XMII Process Order (E.g. Send Control Destination Recipe) Process Order Detail BAPI: BAPI_PROCORD_GET_DETAIL XI Transform the Incoming request to a B2MML Standard XML Message Operation Detail Produnction Resource Tool Componet Material Phase Detail Secondary Resource Produnction Resource Tool Material Consumed Process Instructions Production Schedule Request Receive the B2MML Standard XML Material Produced Requirement Production Parameter(Process Message Order Related Product Segment Process Segment-Operation Operation Primary Resource Secondary Resource S95 Compliance B2MMLShopfloor Production Schedule Application Material Consumed Requirement Send theB2MML Message to Shop floor application Material Consumed Requirement Property Equipment Requirement Equipment Property Personnel Requirement Phase Material Consumed Requirement Material Consumed Requirement Property Equipment Requirement Equipment Property Personnel Requirement Production Parameter(Process Instruction for Phase) SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 14 Example ANSI/ISA-95 Production Performance Process Message Monitor ERP Receive, check and save Process Messages 5 RFC xMII 4 Send Process Messages to ERP 3 Mapping to ERP Process Messages 2 Receive S95 Production Performance XML MES 1 SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 15 Receive control receipt Send S95 Production Performance Example ANSI/ISA-95 Production Performance B2MML Production Performance Production Performance Schema xMII XI PP-PI-PCS Process Message: PI_CRST Control Recipe Status Process Message: PI_PROD Material Produced Actual Material Produced Actual Property Process Message: PI_CONS Material Consumed Actual Process Message: PI_QMSMR PersonnelActual EquipmentActual EquipmentActualProperty SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 16 Process Message: PI_PMMD Example ANSI/ISA-95 Production Performance S95 Compliance Production Performance ShopB2MML Floor Apllication Invoke XMII Production Performance Schema (E.g. Send S95 Control Recipe Status Production Performance) Material Produced Actual Material Produced Actual Property xMII XI PP-PI-PCS Process Message: PI_CRST Process Message: PI_PROD Process Message: PI_CONS Material Consumed Actual Process Message: PI_QMSMR PersonnelActual EquipmentActual EquipmentActualProperty SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 17 Process Message: PI_PMMD Example ANSI/ISA-95 Production Performance S95 Compliance Production Performance ShopB2MML Floor Apllication Invoke XMII Production Performance Schema (E.g. Send S95 Control Recipe Status Production Performance) Material Produced Actual SAP xMII xMII XI Transform the Incoming request to SAP Process Messages Material Produced Actual Property Material Consumed Actual PersonnelActual EquipmentActual EquipmentActualProperty SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 18 PP-PI-PCS Process Message: PI_CRST Process Message: PI_PROD Process Message: PI_CONS Send the Process Messages to ERP Process Message: PI_QMSMR Process Message: PI_PMMD Example ANSI/ISA-95 Production Performance S95 Compliance Production Performance ShopB2MML Floor Apllication Invoke XMII Production Performance Schema (E.g. Send S95 Control Recipe Status Production Performance) Material Produced Actual SAP xMII xMII XI Transform the Incoming request to SAP Process Messages Material Produced Actual Property Material Consumed Actual PersonnelActual EquipmentActual EquipmentActualProperty SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 19 Send theB2MML Message to Shop floor application SAP ERP PP-PI-PCS Receive, check and Process Message: PI_CRST save process messages Process Message: PI_PROD Process Message: PI_CONS Process Message: PI_QMSMR Process Message: PI_PMMD Example A: Directly Integrate „Production Line“ using xMII SAP ERP Manufacturing Download Order Upload Confirmation SAP xMII: Business Content Business Logic for triggering messages and data checks (Logical Integration ) SAP xMII Business Logic „S95 enhanced“ Standard Mapping e.g. ANSI/ISA-95 Buffering Connector Framework S95 Production Schedule S95 Production Performance Shop Floor Automation and Control Systems (SFAC) SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 20 Monitoring (Business View) Data Buffering ( e.g. Orders per shift) Example A: Directly Integrate „Production Line“ using xMII SAP ERP Manufacturing Download Order Upload Confirmation SAP xMII: Business Content Business Logic for triggering messages and data checks (Logical Integration ) SAP xMII Business Logic „S95 enhanced“ Standard Mapping e.g. ANSI/ISA-95 Buffering Connector Framework Monitoring (Business View) Data Buffering ( e.g. Orders per shift) Delivery and Support Shop Floor Connectors Transformation, Aggregation and Mapping Message Queuing and Logging S95 Production Schedule S95 Production Performance Used for Synchronous and Asynchronous Message Transfer Visualization and Retry Shop Floor Automation and Control Systems (SFAC) SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 21 Capabilities Example B: Integrate „Third Party MES System“ using xMII SAP ERP Manufacturing Upload Confirmation Download Order SAP xMII: Business Content Business Logic for triggering messages and data checks (Logical Integration ) SAP xMII Business Logic „S95 enhanced“ Standard Mapping e.g. ANSI/ISA-95 Connector Framework Monitoring (Business View) Delivery and Support Shop Floor Connectors Transformation, Aggregation and Mapping Message Queuing and Logging S95 Production Schedule Buffering S95 Production Performance Third Party MES Systems SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 22 Used for Synchronous and Asynchronous Message Transfer Visualization and Retry Capabilities Example C: „Integrate Plant Systems“ using XI and xMII SAP ERP Manufacturing SAP XI: Technical Content Technical Monitoring of Messages Transformation and Mapping Download Order Upload Confirmation Message Queuing and Logging Retry Capabilities Higher Payload Size Processing Aggregated Data SAP XI Mostly Used for Asynchonous Message Transfer ERP Shop Floor Subsystem 1 Subsystem 2 synchronous asynchronous SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 23 Example C: „Integrate Plant Systems“ using XI and xMII SAP ERP Manufacturing SAP XI: Technical Content Transformation and Mapping Technical Monitoring of Messages Download Order Upload Confirmation Message Queuing and Logging Retry Capabilities Higher Payload Size Processing Aggregated Data SAP XI Mostly Used for Asynchonous Message Transfer ERP Shop Floor SAP xMII: Business Content Business Logic for triggering messages and data checks (Logical Integration ) Monitoring (Business View) Subsystem 1 Subsystem 2 SAP xMII Data Buffering ( e.g. Orders per shift) Delivery and Support Shop Floor Connectors Transformation, Aggregation and Mapping Message Queuing and Logging Used for Synchronous and Asynchronous Message Transfer synchronous asynchronous SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 24 Visualization and Retry Capabilities Interfaces in production? ERP MES Save Correlation Historian I Historian II SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 25 Analyse LIMS Correlation Plant ‘Home-Grown‘ Maintenance Integration of the production with SAP xMII ERP Data extraction Data in correlation Data analyses xMII xMII Historian I MES Historian II ‘Home-Grown‘ LIMS SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 26 Plant Maintenance SAP xMII functionality in comparison with MES systems ERP System Integration SAP xMII Intelligence Data Connectors Non SAP System Excel SQL or Access Historian SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 27 Custom Database Correlation of Data from Different Sources 1 4 1. Look up customer SO from ERP & return ERP Production Order 2. Find Batch(es) created to satisfy Production Order 3. Get Historian and LIMS data for batches, run xMII Analytics 4. If SPC Alarm it is a Batch production problem – provide aggregate view of LOTS & CUSTOMERS 5. Email report to Product Manager, Disposition to SAP QM, Close record in QN System 2 3 5 SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 28 How can SAP help? Interoperability Scenarios – Best Practises Proactive Solution Monitoring SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 29 What are the problems ? SAP ERP Manufacturing Send Production Order Upload Confirmation SAP xMII Business Logic „S95 enhanced“ Standard Mapping e.g. ANSI/ISA-95 Connector Framework S95 Production Schedule Buffering S95 Production Performance MES System SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 30 What are the problems ? SAP ERP Manufacturing Send Production Order Upload Confirmation SAP xMII Business Logic „S95 enhanced“ Standard Mapping e.g. ANSI/ISA-95 Connector Framework S95 Production Schedule Buffering S95 Production Performance MES System SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 31 What are the requirements ? ERP xMII Proactive Monitoring 1 Send Production Order 2 Receive Order 3 Mapping to S95 production schedule 4 Send S95 production schedule messages to MES System MES SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 32 5 Receive, check and save S95 production schedule messages 6 Complete order data and save What are the requirements ? ERP xMII Proactive Monitoring 1 Send Production Order 2 Receive Order 3 Mapping to S95 production schedule 4 Send S95 production schedule messages to MES System MES SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 33 5 Receive, check and save S95 production schedule messages 6 Complete order data and save What are the requirements ? ERP xMII Scope Responsibility 1 Send Production Order 2 Receive Order 3 Mapping to S95 production schedule 4 Send S95 production schedule messages to Wonderware MES SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 34 5 Receive, check and save S95 production schedule messages 6 Complete order data and save What are the requirements ? 1. Allow supervision of configurable manufacturing processes from ERP to Shop floor (or Shop Floor to EP) including message exchange and message processing in the affected systems. 2. Trigger alerts for processes which either show errors or show ‘hanging’ steps. Alerts should be visible in a dashboard. 3. Allow follow-up action on individual processes either as drill down or corrective action. 4. Support high data volumes of process messages to be usable in shop floor scenarios. 5. Must be easy to configure and easy to use . 6. Should run on existing mySAP ERP or on separate SAP instance SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 35 Customer Prototype: ERP Process Monitoring Package RFC SAP Solution Manager System Monitoring Business Process Monitoring Service Level Reporting System Monitoring 1 Send Control Recipe xMII 2 Receive Recipe 3 Mapping to S95 production schedule System Monitoring 4 WEB Service MES System Monitoring Status & Info Reporting SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 36 Send S95 production schedule messages to the MES-system 5 Receive, check and save S95 production schedule messages 6 Complete order data and save Customer Prototype: ERP Process Monitoring Package RFC SAP Solution Manager System Monitoring Business Process Monitoring Service Level Reporting System Monitoring 1 Send Control Recipe xMII 2 Receive Recipe 3 Mapping to S95 production schedule System Monitoring 4 WEB Service MES System Monitoring Status & Info Reporting SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 37 Send S95 production schedule messages to the MES-system 5 Receive, check and save S95 production schedule messages 6 Complete order data and save Customer Prototype: ERP Process Monitoring Package RFC SAP Solution Manager System Monitoring Business Process Monitoring Service Level Reporting System Monitoring 1 Send Control Recipe xMII 2 Receive Recipe 3 Mapping to S95 production schedule System Monitoring 4 WEB Service MES System Monitoring Status & Info Reporting SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 38 Send S95 production schedule messages to the MES-system 5 Receive, check and save S95 production schedule messages 6 Complete order data and save Example Process Definition SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 39 Process Monitoring Cockpit SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 40 Central Alert Handling Alert Dashboard in xMII: SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 41 Agenda : SAP Manufacturing and Interoperability What is the situation today ? What are the problems ? What are the objectives ? How can SAP help ? What are the benefits? SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 42 Value to Customers Cost Reduction per minimizing the number of interfaces, layers and data maintenance. Standardize the interfaces based on ANSI/ISA-95 B2MML messages. Improved usability and proactive solution monitoring. Visualization and reporting of production relevant data from all involved levels from the shop floor to my SAP Business Suite. SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 43 Summary Interoperability is the ability of production applications and manufacturing business applications to share information and exchange services with each other based on standards. Depending on the required scenarios and the size of the company SAP XMII alone or complementary used together with SAP XI can help to improve the interoperabilty. A proactive solution monitoring can help to monitor the systems and to control the route of the message transport. SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 44 Example? Example ANSI/ISA-95 Production Schedule SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 45 Create Control Recipe SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 46 Material List SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 47 Operations SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 48 Process Instructions SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 49 Process Instructions SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 50 Control Recipe Monitor SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 51 Pocess Monitoring Cockpit SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 52 Process Monitoring Cockpit – Drill Down in ERP SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 53 Process Monitoring Cockpit – Drill Down in xMII SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 54 Central Alert Handling Alert Dashboard in xMII: SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 55 Copyright 2006 SAP AG. 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