Microsoft Juergen_Denver_Manufacturing_Interoperability S95 14 Wettengl
User Manual: S95
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SAP Manufacturing &
Interoperability
Jürgen Wettengl
ASM Manufacturing, SAP AG
SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 2
Agenda : SAP Manufacturing and Interoperability
What are the benefits?
What is the situation today ?
What are the problems ?
What are the objectives ?
How can SAP help ?
SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 3
Kitchen
All
In One
SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 4
* Shop Floor Automation and Control Systems
ERP
SFAC*
ERP
MES
SFAC*
ERP
Manufacturing Business Processes
What is the situation today ?
SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 5
* Shop Floor Automation and Control Systems
ERP
SFAC*
ERP
MES
SFAC*
ERP
Disconnect
Disconnect
Disconnect
Manufacturing Business Processes
What are the problems ?
SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 6
Why use standards like ANSI/S95?
Legacy-System
SPS
LIMS
SCADA
Datenbanken
Tabellen-
kalkulation
HMI
DCS
MM PP
QMPP/PI
PM History
Plant
Systems
Plant
Systems
kundeneigenes
System
SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 7
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 / 8
Agenda : SAP Manufacturing and Interoperability
What are the benefits?
What is the situation today ?
What are the problems ?
What are the objectives ?
How can SAP help ?
SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 9
How can SAP help?
Interoperability Scenarios – Best Practices
Proactive Solution Monitoring
SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 10
Example ANSI/ISA-95 Production Schedule
ERP
xMII
MES
Send Control Recipe
Receive Control Recipe
Mapping to S95
production schedule
Send S95 production
schedule messages to
MES system
Receive, check and save
S95 production schedule
messages
Complete order data
and save
1
2
3
4
5
6
Control
Recipe
Monitor
SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 11
Example ANSI/ISA-95 Production Schedule
Control Recipe Header
Process Order Detail
BAPI: BAPI_PROCORD_GET_DETAIL
Operation Detail
Phase Detail
Componet Material
Primary Resource
Secondary Resource
Produnction Resource Tool
Process Instructions
Process Order
Destination
Secondary Resource
Produnction Resource Tool
Material Consumed
Production Schedule Request
Product Segment
Material Produced Requirement
Process Segment-Operation
Operation
Material Consumed Requirement
Equipment Requirement
Equipment Property
Material Consumed Requirement Property
Phase
Material Consumed Requirement
Equipment Requirement
Equipment Property
Material Consumed Requirement Property
Production Parameter(Process
Order Related
Personnel Requirement
Personnel Requirement
Production Parameter(Process Instruction
for Phase)
PP-PI-PCS XI B2MML Production Schedule
xMII
SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 12
Example ANSI/ISA-95 Production Schedule
Control Recipe Header
Process Order Detail
BAPI: BAPI_PROCORD_GET_DETAIL
Operation Detail
Phase Detail
Componet Material
Primary Resource
Secondary Resource
Produnction Resource Tool
Process Instructions
Process Order
Destination
Secondary Resource
Produnction Resource Tool
Material Consumed
Production Schedule Request
Product Segment
Material Produced Requirement
Process Segment-Operation
Operation
Material Consumed Requirement
Equipment Requirement
Equipment Property
Material Consumed Requirement Property
Phase
Material Consumed Requirement
Equipment Requirement
Equipment Property
Material Consumed Requirement Property
Production Parameter(Process
Order Related
Personnel Requirement
Personnel Requirement
Production Parameter(Process Instruction
for Phase)
PP-PI-PCS XI B2MML Production Schedule
xMII
Invoke XMII
(E.g. Send Control
Recipe)
SAP ERP
SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 13
Example ANSI/ISA-95 Production Schedule
Control Recipe Header
Process Order Detail
BAPI: BAPI_PROCORD_GET_DETAIL
Operation Detail
Phase Detail
Componet Material
Primary Resource
Secondary Resource
Produnction Resource Tool
Process Instructions
Process Order
Destination
Secondary Resource
Produnction Resource Tool
Material Consumed
Production Schedule Request
Product Segment
Material Produced Requirement
Process Segment-Operation
Operation
Material Consumed Requirement
Equipment Requirement
Equipment Property
Material Consumed Requirement Property
Phase
Material Consumed Requirement
Equipment Requirement
Equipment Property
Material Consumed Requirement Property
Production Parameter(Process
Order Related
Personnel Requirement
Personnel Requirement
Production Parameter(Process Instruction
for Phase)
PP-PI-PCS XI B2MML Production Schedule
xMII
Invoke XMII
(E.g. Send Control
Recipe)
SAP ERP
Transform the
Incoming request to
a B2MML Standard
XML Message
Send theB2MML
Message to Shop
floor application
SAP xMII
SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 14
Example ANSI/ISA-95 Production Schedule
Control Recipe Header
Process Order Detail
BAPI: BAPI_PROCORD_GET_DETAIL
Operation Detail
Phase Detail
Componet Material
Primary Resource
Secondary Resource
Produnction Resource Tool
Process Instructions
Process Order
Destination
Secondary Resource
Produnction Resource Tool
Material Consumed
Production Schedule Request
Product Segment
Material Produced Requirement
Process Segment-Operation
Operation
Material Consumed Requirement
Equipment Requirement
Equipment Property
Material Consumed Requirement Property
Phase
Material Consumed Requirement
Equipment Requirement
Equipment Property
Material Consumed Requirement Property
Production Parameter(Process
Order Related
Personnel Requirement
Personnel Requirement
Production Parameter(Process Instruction
for Phase)
PP-PI-PCS XI B2MML Production Schedule
xMII
Invoke XMII
(E.g. Send Control
Recipe)
SAP ERP
Transform the
Incoming request to
a B2MML Standard
XML Message
Send theB2MML
Message to Shop
floor application
SAP xMII
Receive the B2MML
Standard XML
Message
S95 Compliance
Shopfloor Application
SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 15
Example ANSI/ISA-95 Production Performance
ERP
xMII
MES Send S95 Production
Performance
Receive control receipt
Mapping to ERP Process
Messages
Send Process
Messages to
ERP
Receive, check and save
Process Messages
Receive S95
Production Performance
1
2
3
4
5
XML
RFC
Process
Message
Monitor
SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 16
Example ANSI/ISA-95 Production Performance
B2MML Production Performance XI PP-PI-PCS
Production Performance Schema
PersonnelActual
EquipmentActual
Material Produced Actual
Material Consumed Actual
Control Recipe Status
Material Produced Actual Property
EquipmentActualProperty
Process Message: PI_CRST
Process Message: PI_PROD
Process Message: PI_CONS
Process Message: PI_QMSMR
Process Message: PI_PMMD
xMII
SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 17
Example ANSI/ISA-95 Production Performance
B2MML Production Performance XI PP-PI-PCS
Production Performance Schema
PersonnelActual
EquipmentActual
Material Produced Actual
Material Consumed Actual
Control Recipe Status
Material Produced Actual Property
EquipmentActualProperty
Process Message: PI_CRST
Process Message: PI_PROD
Process Message: PI_CONS
Process Message: PI_QMSMR
Process Message: PI_PMMD
xMII
Invoke XMII
(E.g. Send S95
Production
Performance)
S95 Compliance
Shop Floor Apllication
SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 18
Example ANSI/ISA-95 Production Performance
B2MML Production Performance XI PP-PI-PCS
Production Performance Schema
PersonnelActual
EquipmentActual
Material Produced Actual
Material Consumed Actual
Control Recipe Status
Material Produced Actual Property
EquipmentActualProperty
Process Message: PI_CRST
Process Message: PI_PROD
Process Message: PI_CONS
Process Message: PI_QMSMR
Process Message: PI_PMMD
xMII
Invoke XMII
(E.g. Send S95
Production
Performance)
S95 Compliance
Shop Floor Apllication
Transform the
Incoming request to
SAP Process
Messages
Send the Process
Messages to ERP
SAP xMII
SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 19
Example ANSI/ISA-95 Production Performance
B2MML Production Performance XI PP-PI-PCS
Production Performance Schema
PersonnelActual
EquipmentActual
Material Produced Actual
Material Consumed Actual
Control Recipe Status
Material Produced Actual Property
EquipmentActualProperty
Process Message: PI_CRST
Process Message: PI_PROD
Process Message: PI_CONS
Process Message: PI_QMSMR
Process Message: PI_PMMD
xMII
Invoke XMII
(E.g. Send S95
Production
Performance)
S95 Compliance
Shop Floor Apllication
Transform the
Incoming request to
SAP Process
Messages
Send theB2MML
Message to Shop
floor application
SAP xMII
Receive, check and
save process
messages
SAP ERP
SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 20
SAP xMII Business Logic
Buffering
„S95 enhanced“ Standard Mapping
e.g. ANSI/ISA-95
Connector Framework
Example A: Directly Integrate „Production Line“ using xMII
Download
Order
Download
Order
Upload
Confirmation
Upload
Confirmation
S95
Production
Schedule
S95
Production
Schedule
S95
Production
Performance
S95
Production
Performance
Shop Floor Automation
and Control Systems
(SFAC)
SAP ERP Manufacturing
SAP xMII: Business Content
Business Logic for triggering messages and
data checks (Logical Integration )
Monitoring (Business View)
Data Buffering ( e.g. Orders per shift)
SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 21
SAP xMII Business Logic
Buffering
„S95 enhanced“ Standard Mapping
e.g. ANSI/ISA-95
Connector Framework
Example A: Directly Integrate „Production Line“ using xMII
Download
Order
Download
Order
Upload
Confirmation
Upload
Confirmation
S95
Production
Schedule
S95
Production
Schedule
S95
Production
Performance
S95
Production
Performance
Shop Floor Automation
and Control Systems
(SFAC)
SAP ERP Manufacturing
SAP xMII: Business Content
Business Logic for triggering messages and
data checks (Logical Integration )
Monitoring (Business View)
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
Visualization and Retry Capabilities
SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 22
SAP xMII Business Logic
Connector Framework
Example B: Integrate „Third Party MES System“ using xMII
Download
Order
Download
Order
Upload
Confirmation
Upload
Confirmation
S95
Production
Schedule
S95
Production
Schedule
S95
Production
Performance
S95
Production
Performance
Third Party MES Systems
SAP ERP Manufacturing
„S95 enhanced“ Standard Mapping
e.g. ANSI/ISA-95
Buffering
SAP xMII: Business Content
Business Logic for triggering messages and
data checks (Logical Integration )
Monitoring (Business View)
Delivery and Support Shop Floor Connectors
Transformation, Aggregation and Mapping
Message Queuing and Logging
Used for Synchronous and Asynchronous
Message Transfer
Visualization and Retry Capabilities
SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 23
Example C: „Integrate Plant Systems“ using XI and xMII
Download
Order
Download
Order
Upload
Confirmation
Upload
Confirmation
SAP ERP Manufacturing
SAP XI
Subsystem 1
Shop Floor
ERP
SAP XI: Technical Content
Technical Monitoring of Messages
Transformation and Mapping
Message Queuing and Logging
Retry Capabilities
Higher Payload Size
Processing Aggregated Data
Mostly Used for Asynchonous
Message Transfer
Subsystem 2
asynchronous
synchronous
SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 24
Example C: „Integrate Plant Systems“ using XI and xMII
Download
Order
Download
Order
Upload
Confirmation
Upload
Confirmation
SAP ERP Manufacturing
SAP XI
Subsystem 1
Shop Floor
ERP
SAP xMII: Business Content
Business Logic for triggering messages and
data checks (Logical Integration )
Monitoring (Business View)
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
Visualization and Retry Capabilities
SAP XI: Technical Content
Transformation and Mapping
Technical Monitoring of Messages
Message Queuing and Logging
Retry Capabilities
Higher Payload Size
Processing Aggregated Data
Mostly Used for Asynchonous
Message Transfer
Subsystem 2 SAP xMII
asynchronous
synchronous
SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 25
Plant
Maintenance
Historian IIHistorian I LIMS
MES
‘Home-Grown‘
Correlation Correlation
Interfaces in production?
Analyse
Save
ERP
SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 26
Integration of the production with SAP xMII
xMII
xMII
Plant
Maintenance
Historian II
Historian I
LIMS
‘Home-Grown‘
MES
ERP
Data in correlation
Data analyses
Data extraction
SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 27
SAP xMII functionality in comparison with MES systems
ERP System
Integration Intelligence
SAP xMII
Historian Custom
Database
Non SAP
System
Excel
SQL or
Access
Data Connectors
SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 28
5. Email report to Product
Manager, Disposition to
SAP QM, Close record
in QN System
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
1. Look up customer SO
from ERP & return ERP
Production Order
1
2
5
3
4
Correlation of Data from Different Sources
SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 29
How can SAP help?
Interoperability Scenarios – Best Practises
Proactive Solution Monitoring
SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 30
SAP xMII Business Logic
Connector Framework
What are the problems ?
Send
Production
Order
Send
Production
Order
Upload
Confirmation
Upload
Confirmation
S95
Production
Schedule
S95
Production
Schedule
S95
Production
Performance
S95
Production
Performance
MES System
SAP ERP Manufacturing
„S95 enhanced“ Standard Mapping
e.g. ANSI/ISA-95
Buffering
SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 31
SAP xMII Business Logic
Connector Framework
What are the problems ?
Send
Production
Order
Send
Production
Order
Upload
Confirmation
Upload
Confirmation
S95
Production
Schedule
S95
Production
Schedule
S95
Production
Performance
S95
Production
Performance
MES System
SAP ERP Manufacturing
„S95 enhanced“ Standard Mapping
e.g. ANSI/ISA-95
Buffering
SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 32
What are the requirements ?
ERP
xMII
MES
Send Production Order
Receive Order
Mapping to S95
production schedule
Send S95 production
schedule messages to
MES System
Receive, check and save
S95 production schedule
messages
Complete order data
and save
1
2
3
4
5
6
Proactive
Monitoring
SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 33
What are the requirements ?
ERP
xMII
MES
Send Production Order
Receive Order
Mapping to S95
production schedule
Send S95 production
schedule messages to
MES System
Receive, check and save
S95 production schedule
messages
Complete order data
and save
1
2
3
4
5
6
Proactive
Monitoring
SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 34
What are the requirements ?
ERP
xMII
MES
Send Production Order
Receive Order
Mapping to S95
production schedule
Send S95 production
schedule messages to
Wonderware
Receive, check and save
S95 production schedule
messages
Complete order data
and save
1
2
3
4
5
6
Scope
Responsibility
SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 35
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
What are the requirements ?
SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 36
Customer Prototype:
ERP
xMII
MES
Send Control Recipe
Receive Recipe
Mapping to S95
production schedule
Send S95 production
schedule messages to
the MES-system
Receive, check and save
S95 production schedule
messages
Complete order data
and save
System
Monitoring 1
2
3
4
5
6
Process Monitoring
Package
RFC
WEB Service
System
Monitoring
System
Monitoring
Status & Info Reporting
SAP
Solution Manager
System Monitoring
Business Process Monitoring
Service Level Reporting
SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 37
Customer Prototype:
ERP
xMII
MES
Send Control Recipe
Receive Recipe
Mapping to S95
production schedule
Send S95 production
schedule messages to
the MES-system
Receive, check and save
S95 production schedule
messages
Complete order data
and save
System
Monitoring 1
2
3
4
5
6
Process Monitoring
Package
RFC
WEB Service
System
Monitoring
System
Monitoring
Status & Info Reporting
SAP
Solution Manager
System Monitoring
Business Process Monitoring
Service Level Reporting
SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 38
Customer Prototype:
ERP
xMII
MES
Send Control Recipe
Receive Recipe
Mapping to S95
production schedule
Send S95 production
schedule messages to
the MES-system
Receive, check and save
S95 production schedule
messages
Complete order data
and save
System
Monitoring 1
2
3
4
5
6
Process Monitoring
Package
RFC
WEB Service
System
Monitoring
System
Monitoring
Status & Info Reporting
SAP
Solution Manager
System Monitoring
Business Process Monitoring
Service Level Reporting
SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 39
Example Process Definition
SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 40
Process Monitoring Cockpit
SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 41
Alert Dashboard in xMII:
Central Alert Handling
SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 42
Agenda : SAP Manufacturing and Interoperability
What are the benefits?
What is the situation today ?
What are the problems ?
What are the objectives ?
How can SAP help ?
SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 43
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 / 44
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 / 45
Example?
Example ANSI/ISA-95 Production Schedule
SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 46
Create Control Recipe
SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 47
Material List
SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 48
Operations
SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 49
Process Instructions
SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 50
Process Instructions
SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 51
Control Recipe Monitor
SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 52
Pocess Monitoring Cockpit
SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 53
Process Monitoring Cockpit – Drill Down in ERP
SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 54
Process Monitoring Cockpit – Drill Down in xMII
SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 55
Alert Dashboard in xMII:
Central Alert Handling
SAP AG 2006, SAP Manufacturing & Interoperability / Jürgen Wettengl / 56
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