Integrating with Enterprise Resource Planning (ERP) Systems (L4), Equipment and Controllers (L2) to Produce a Flexible MES System

Transcription

1 Integrating with Enterprise Resource Planning (ERP) Systems (L4), Equipment and Controllers (L2) to Produce a Flexible MES System Daniel O. Trivino Senior MES Engineer CSL Behring, Kankakee, IL CBI's 12th Annual Life Science Forum on Manufacturing Execution Systems in Orlando, FL - August 15-16, 2017

2 A. CSL Behring Overview B. Best Practices for a Successful Integration PRESENTATION DISCUSSION TOPICS 2

3 CSL Behring Subsidiary of CSL Limited, a biotechnology company with headquarters in Melbourne, Australia 14,000+ employees worldwide Operational headquarters in King of Prussia, Pennsylvania, USA Six research facilities around the world Four manufacturing facilities on three continents, with a fifth facility currently under construction. 3

4 Kankakee Finished Products Albuminar AlbuRx Zemaira Monoclate P Mononine Afluria (Fill and Finish Only) Urgent restoration of blood volume, e.g. surgical setting for trauma, burns, shocks. Alpha 1-proteinase for alpha-1 antitrypsin deficiency Treatment or prevention of bleeding episodes as a result of Hemophilia A Treatment or prevention of bleeding episodes as a result of Hemophilia B Influenza Virus Vaccine 4

5 A. Why integrate? B. Integration approach BEST PRACTICES FOR A SUCCESSFUL INTEGRATION (LEVEL 4 AND LEVEL 3) 5

6 Integrating MES with ERP BT Landscape ISA 95 Layers Level 4 SAPBusiness Management Planning & Logistics Generate/Manage Orders, BOMS, Inventory, Basic Production Schedule Level 3 Manufacturing Operations Management Production Management Inventory Operations Quality Operations Maintenance Operations Level 2 Discrete Control Batch Control Continuous Control Equipment supervisory control. Automated Process control. SCADA. 6 Level 1 Direct equipment control. PLC s, sensors.

7 Integrating MES with ERP BT Landscape ISA 95 Layers Level 4 SAPBusiness Management Planning & Logistics Generate/Manage Orders, BOMS, Inventory, Basic Production Schedule Level 3 Manufacturing Operations Management Production Management Inventory Operations Quality Operations Maintenance Operations Level 2 Discrete Control Batch Control Continuous Control Equipment supervisory control. Automated Process control. SCADA. 7 Level 1 Direct equipment control. PLC s, sensors.

8 Integrating MES with ERP Why Integrate MES with ERP? Real-time information exchange Increase visibility for shop floor Provide integrated workflow management 8

9 Integrating MES with ERP ERP Material Master Overall Inventory Overall Genealogy Master Batch Record Master Production Schedule Production Orders Master material data Overall inventory Material lot status Production orders Production order status Material consumptions Inventory update 9 MES Production Resource Management Detailed Master Batch Records Production Plan Execution Electronic Batch Recording Review by Exception Material Management in Production

10 10 MES => SAP MO status Start, End, Abort SFO Status Start and End Date of Manufacturing Transports (between MES) Outgoing Transport Inventory Movements Integrating MES with ERP Message exchanges Take from out cost center Scrapping Inventory Adjustment Goods Issues (Material Consumption) Goods Receipts (Stock Creation) SAP => MES Material Master Batch Data (Batch Status) Process Orders Weighmaster Order Incoming Transport Inventory Refresh Inventory Reconciliation

11 Integrating MES with ERP SAP to MES Architecture: 11

12 Integrating MES with ERP SAP to MES Architecture: Shop Order SAP idocs SAP SAP Interface (PI) MES Interface Message type ZPPPROUS XMLs MES 12

13 Integrating MES with ERP 13

14 Integrating MES with ERP 14

15 Integrating MES with ERP 15

16 Integrating MES with ERP 16

17 Manufacturing Floor Improvements IMPROVEMENTS 17

18 Manufacturing Floor Improvements Batch Record Issue: Before Manufacturing would issue paper records Several packets of paper records, from 60 to 80 pages in each packet Manually counted and reviewed paper before issuing to manufacturing floor 18

19 Manufacturing Floor Improvements Batch Record Issue: After Electronic batch record is generated by MES from SAP No paperwork to manufacturing floor Manufacturing knows what will be next on the schedule. 19

20 Manufacturing Floor Improvements Material Usage: Before Operator checked material label to ensure correct & within date Manufacturing manually entered quantity, material & batch numbers into SAP Operator signed and dated the manufacturing record 20

21 Manufacturing Floor Improvements Material Usage: After Operator scans material barcode MES automatically checks status and updates SAP with quantity, material, batch and records the user and date 21

22 Manufacturing Floor Improvements Material Usage: After Error proofing Immediate response 22

23 Conclusion Integrating MES with ERP helps with Real-time information Establish a strong cross functional team Understand business process Establish metrics to show performance improvements 23

24 A. Why integrate? B. Integration approach BEST PRACTICES FOR A SUCCESSFUL INTEGRATION (LEVEL 3 AND LEVEL 2) 24

25 Integrating MES with Level 2 Why Integrate MES with Level 2? Real-time information exchange MES collects quality relevant data and checks against ranges. MES documents quality relevant data in the batch record report 25

26 Level 2 and 3 Integration (MES) SCADA Adapter Tag Base addressing Read and write tags Real Time access DCS / Batch Adapter Recipe base addressing Read and set recipe parameter Real time access Data Historian Adapter Tag or recipe based addressing Read only Access to data some minutes in past only 26

27 Level 2 and 3 Integration PLC PLC PLC 27 27

28 MES Level 2 and 3 Integration Step 2 SCADA DATA Alarms and events Step 1 Step 3 Step 4 SCADA DATA SCADA Adapter Data Historian Adapter PLC PLC PLC 28 28

29 Conclusion Integrating MES with Level 2 helps with Real-time information Establish a strong cross functional team Understand business process 29

30 Comments or questions? Daniel Trivino MES engineer