Molex: A Case Study in Upgrading. Dave Hubert Manager Global Information System Molex

Transcription

1 Molex: A Case Study in Upgrading Dave Hubert Manager Global Information System Molex

2 Support to the Mature Landscape Molex Company is a manufacturer of Electronic Interconnection Systems headquarters in Lisle, Il outside Chicago. $2.2billion sales, 50% pc/telecom, 30% consumer and industrial electronics, 20% automotive. Local site in Auburn Hills. Global Single instances of R/3 plus BW,CRM, APO Solution Manager and limited Portal: Initial go-live in February, 1996, since then over 45 plant/warehouses, sales org companies in 20 countries, 50 or more sales offices access from over 30 countries, using all SAP modules in 10 languages. 10 years with SAP anniversary in August, Over 1800 concurrent of 8000 users 7X24, 2 million + transactions per day in r/3, over 98% of all Molex sites share this one system of 2.5TB. SAP AG 2004, Navigating Successful Upgrades / 2

3 Global Manufacturing & Distribution Locations and SAP Australia Brazil (2) SAP04 Canada SAP99 China (6) SAP98-02 France SAP05 Germany SAP02 India (4) SAP03 Ireland (3) SAP97 Italy SAP 00 Japan (7) SAP99 Korea (3) SAP02 Malaysia SAP 98 Mexico (2) SAP 98,01 Netherlands SAP 98 Poland (2) Portugal SAP 05 Singapore SAP 96 Slovakia (2) SAP 01 Taiwan SAP 97 Thailand SAP 99 United States (15) SAP SAP AG 2004, Navigating Successful Upgrades / 3

4 History of Upgrades R/3 First Development fall, 1994 using 2.1D. First Production site implementation February, 1996 using 2.2E. First Live Upgrade from 2.2E to 3.0D in November, Hot Packs to 3.0D from Upgrade from 3.0D to 46B patch 15 Nov.,00. Most Difficult. Support packs to 46b summer 01. Upgrade from 46b 26 to 46c sp25 Jan 02. Support packs c fall 02. Support packs c spring 03. Upgrade 46c to 470 sp17 (basis ) March, Support packs summer 04, DIMP471 Industry Dec., 04. SAP AG 2004, Navigating Successful Upgrades / 4

5 History of Upgrades non R/3 CRM live at 2.0 in June, 2001 CRM upgrade to 3.1 in July, 2003 CRM upgrade to 4.0 in September, 2004 BW live at 2.1 in May, 2001 BW upgrade to 3.0 in September, 2002 BW upgrade to 3.5 in Spring, 2005 APO installed at 3.1 in April, 2003 live December, APO upgrade to 4.0 or 4.1 in Spring Summer, Support packs to all systems about every 8 months. SAP AG 2004, Navigating Successful Upgrades / 5

6 4.7 Enterprise Upgrade Result Oracle upgraded in January, Plug in Upgraded in February, PDB D&B add-on upgraded in February, Prior to the actual upgrade SAPGUI was a mix of patch Predominately patch 26 in our Far East South Operations, 42 in Japan and parts of America and Europe. Various in the rest of America and Europe. Now mostly patch 43 (BW 3.0 7) Actual Upgrade completed in 15 hours on a Saturday. Significant involvement of BW team to properly clear BW delta queues and post upgrade steps. Post upgrade problems mostly in the area of Logistics Execution, variants changed, abap queries and a change in the use or product cost version within activity prices. SAP AG 2004, Navigating Successful Upgrades / 6

7 Schedule for 4.7 Upgrade Determined comparable level of 46c to 470 as coming together around 46c patch c 45 contains similar functionality corrections to 470 sp 15. Many of the applications are not significantly changed in 470. The underlying basis level is changed to 620. Original estimate was an August 03 to Jan 04 timeline. Technical failures in the basis upgrade process caused by SAP programs delayed the timeline to March 04. Significant SAP process changes in Dec 03 for the technical rgup basis procedure. Go live check identified similar issues to those we knew. Oracle needed to upgrade to (no less than that due to bugs), plug in needed to upgrade to We would upgrade these in production prior to the Enterprise upgrade. SPAU significantly more detailed and significant to user exits and custom data structures than in prior upgrades. SAP AG 2004, Navigating Successful Upgrades / 7

8 Time Spent on the Hr. Core Configuration team 2500 Hours. Basis Team 600 hours. Regional Support Team Europe 500 hours. Regional Support Far East So hours. Regional Support Far East No. 500 hours. Regional Support Americas 500 hr. Corp ABAP/EDI 1500 hr. Abap outsource programs) 700 hr. SAP AG 2004, Navigating Successful Upgrades / 8

9 Upgrade Preparations in a Complex Landscape SAPGUI is universal and must correspond to the highest BASIS release until 620, then either 620 or 640 can be used. This should be done well in advance so that all users have the appropriate GUI during the test phase. The plug-in is used to communicate among the various systems and therefore needs careful coordination. Best practice we have found is to separate this from the application upgrade. Underlying database may also require an upgrade (We use Oracle for r/3,bw, CRM and SAPDB for APO). Best practice has been to separate that upgrade from the application upgrade. The normal landscape becomes a dual maintenance landscape -. Dev>QA>Staging>Production becomes QAdev>staging>production. Upgrade is Dev>upgrade-qa. SAP AG 2004, Navigating Successful Upgrades / 9

10 Upgrade Planning and Execution Steps Coordinate basis, hardware, application support, and business schedules. Register the upgrade with OSS and take advantage of the functional checks per your maintenance agreement. Review with similar companies, for example in your sector met through ASUG or as facilitated by SAP. Plan 2 or 3 production copy and sandbox upgrades prior to tackling your Dev system where there is no going back. Plan 2 or 3 production copy upgrades after the Dev box is done using preserved post upgrade transports. Register with OSS for the upgrade weekend. Expect to apply OSS fixes in the 2 weeks following the upgrade. SAP AG 2004, Navigating Successful Upgrades / 10

11 SAP and the Experienced Upgrade Team Our 3.0D to 4.6B upgrade in November, 2000 required on site basis support, some Oracle DBA support, and an on site escalation manager. We also lost 1.5 business days due to the length of time it took to perform that upgrade. Based upon that experience we have never lost another business day and have not needed on site support during any of our subsequent upgrades. Upgrades are done by experienced basis and application support and are completed on weekends. SAP now fills 3 rolls 1 Performance tuning technical support such as SMO (solution management optimization). 2 Initial implementation guidance for a new project such as the Demand Planning Service Select with APO. 3 OSS liaison and escalation. SAP AG 2004, Navigating Successful Upgrades / 11

12 SMO Solution Management Optimization Post upgrade to 470 we identified statistical degradation of response time and increasing CPU utilization. We made some progress by applying OSS notes, working on indexes and kernel changes but finally engaged an SMO team from Active Global Support. Last used in 46c for Business Process Period Close Optimization, these services combine advice on procedures and configuration but the SMO technical team adds a full investigation of system parameters, sql cache and program advice. We have engaged these teams about every 1 ½ to 2 years since the days of 30d. We have had data archiving teams, technical support teams and most recently the SMO teams. Teams review the system remotely first and then a 3 or 4 person team is on site for about 4 days to review the system operation. This is in much more useful detail than the post upgrade standard functional check. SAP AG 2004, Navigating Successful Upgrades / 12

13 Initial Implementation Support DP APO We thought we could tackle DP in APO as a side job because we were very experienced in r/3 flexible planning. However, time for the side job never became available. In May 2003 Molex engaged SAP on piloting the APO Demand Planning Service Select Package The Service Select Package is configured with standard structures and processes as templates to be readily adapted by most businesses demand planning tasks Molex started the Adaptation process in September 2003 with the help from of SAP 2 to 3 working days per week schedule Duplicated and improved on the existing Demand Planning SOP system workable pilot in 30 days (10-14 consulting plus 1 Molex support person) SAP AG 2004, Navigating Successful Upgrades / 13

14 Production Service Select Support DP APO Fast Adaptation and Implementation It took 40 working days of consultant s available schedule to complete the whole project including recreation of data sets unique to our requirements. APO was fully functional in December 2003 (3 months after the start of Molex Adaptation) exactly as planned. Required limited resources One SAP consultant, 40 days One person in configuration, part-time One person in BW interface, occasional One person in Basis, occasional *** Molex had the advantage of having a fully functional design in SOP. We saved much time not to have to start from scratch. SAP AG 2004, Navigating Successful Upgrades / 14

15 Performance Benefit of APO DP Vs R/3 Flex Planning R/3 25 jobs running over 400 hours to set the baseline forecast. Average time to open an entire plant s forecast of all items up to 3.5 hours. 80 Planning Types, 17 info structures and 20 copy programs to manage. Reduced the total cycle time to 2 days while improving all aspects of usability and system performance. Typical user completes work in 1/10 th the time. Implementation cost consult, travel, train < ½ yr. Maint. APO 20 jobs running 90 hours to set the baseline forecast. Average time to open an entire plant s forecast of all items less than 1 minute. 36 Planning Books, 9 info cubes and 4 copy programs to manage. Significant improvement with macro calculations. SAP AG 2004, Navigating Successful Upgrades / 15

16 Successful use of SAP Resources Maintain a continual relationship with SAP s consulting engagement management, with your SAP account executive and with your contacts at Active Global Support (OSS management). We meet companies who don t even know their account management team and interact only through OSS messages. Be active with ASUG and other SAP user groups to share information. Stay ahead of the game with research at service.marketplace. Coordinate your internal expertise to leverage SAP expertise. Knowledge transfer is essential. SAP AG 2004, Navigating Successful Upgrades / 16

17 Next Upgrades at Molex DIMP 4.71 discrete industry completed in December, BW to upgrade to April to June, APO trial to 4.0 completed in March but will be deferred until BW is complete. EBP install in the fall of ICH to install early Next R/3 upgrade likely to be to the ECC 6.0 release in late summer or early fall of SAP AG 2004, Navigating Successful Upgrades / 17

18 Q & A Questions? SAP AG 2004, Navigating Successful Upgrades / 18