Exaquantum Manufacturing Data Exchange Exaquantum/MDX

Transcription

1 Exaquantum Manufacturing Data Exchange Exaquantum/MDX - 1 -

2 Exaquantum Family Diagram ERP Laboratory Maintenance 3 rd Party Products Server Manufacturing Data Exchange Exaquantum/MDX LIMS Data Exchange Exaquantum/LDX Data Integration APIs, Files, ODBC, OLE DB, OPC DA & HDA, Web Services Event Service Exaquantum/EES Alarm Management Safety Management Production Management Energy Management Operator Effectiveness Sequence of Events Recorder Exaquantum/SER Alarm Reporting and Analysis Exaquantum/ARA Alarm Master Database Exaquantum/AMD Subsea Portal Exaquantum/SSP Safety Function Monitoring Exaquantum/SFM Override Safety Advisor Exaquantum/OSA Down Time Analysis Exaquantum/DTA Movements Monitoring Visa-OM Power Performance Calcs Exaquantum/PPC Report Manager Exaquantum/RM Graphical Framework Exaquantum/GF Operator Trending Module Exaquantum/OTM AutoTrend Exaquantum/AutoTrend Electronic Log Book elogbook Data Historian / PIMS Exaquantum & Exaquantum/Batch Remote Data Synchronization Exaquantum/RDS Exaquantum/BRU Exaquantum/EFI Exaquantum/FDM Exaquantum/HDM Exaquantum/ORM Exaquantum/SDM Exaquantum/VPN OPC DCS Safety SCADA PLC - 2 -

3 ISA-95 & ERP Integration ISA-95 is the framework for ERP and related applications to integrate with the MES and production Yokogawa is a member of the SP95 committee Yokogawa led the development of B2MML (Business to Manufacturing Mark-up Language) for the WBF (World Batch Forum) SAP and ORACLE support ISA-95: SAP is fully committed to ISA-95 Full support for ISA-95 & B2MML ISA-95 uses B2MML within Exchange Interface (XI) - 3 -

4 SAP Integration & Visualization Data Integration ISA-95/B2MML based Production data exchange Yokogawa systems sends Alerts and KPIs to SAP Loosely coupled, standards based approach lowers cost to implement and TCO compared to previous SAP integration methods Enables increased agility Visualization Configurable manufacturing intelligence dashboards SAP NetWeaver portal users have access to real time shop floor data Seamless display of business and manufacturing data Role based display and access control Enables management by exception - 4 -

5 SAP/Yokogawa Adaptive Manufacturing Alert! Manufacturing Intelligence Dashboards Role-based, configurable, dashboards that deliver alerts, reports, KPIs and decision support to different production personnel (part of mysap ERP) SAP NETWEAVER Manufacturing Intelligence Dashboard Manufacturing Operations Manufacturing planning, execution, quality, maintenance along with environment, health, and safety processes are enabled by mysap ERP Manufacturing Yokogawa MES Manufacturing Integration The solution uses the SAP NetWeaver platform to integrate SAP with Yokogawa MES applications The SAP/Yokogawa Partner Solution enables adaptive manufacturing by providing the business context for manufacturing data and exceptions to close the loop between the factory and the enterprise - 5 -

6 Scenario 1 KPI Alert Alert! 1 Production Manager logs into his SAP Dashboard and sees all critical KPIs are green and within target levels; he goes to a meeting SAP NETWEAVER Manufacturing Intelligence Dashboard 2 Manager returns from his meeting and sees an alert showing the Production Order Cycle Time KPI is red Manufacturing Yokogawa MES 3 Production Manager drills down on the KPI via a realtime Yokogawa iview that displays plant conditions and sees that the Pre-Mix unit is in hold 4 Production Manager and Operations Supervisor for the Pre-Mix area collaborate and agree on the actions to resolve the situation - 6 -

7 Scenario 2 Maintenance Alert Alert! 1 Plant Manager sees an alert pertaining to potential Production Outage on his SAP Manufacturing Intelligence Dashboard SAP NETWEAVER Manufacturing Intelligence Dashboard 2 Manager drills down on the alert to see imminent failure of a pump detected by the condition based maintenance system and passed to the Dashboard in real-time via Yokogawa 3 Plant Manager via Yokogawa iview views current production order statuses Manufacturing Yokogawa MES 4 Plant Manager collaborates with Production and Maintenance Managers, decision made to continue running pump for 2 more shifts in order to complete critical, high profit, orders 5 Plant Manager monitors pump and production statuses using iviews to monitor completion of critical orders and pump maintenance - 7 -

8 Scenario 3 Rush Order Alert! 1 Production Manager received a rush order for a high profit product from a new supply chain customer SAP NETWEAVER Manufacturing Intelligence Dashboard 2 Manager uses the Manufacturing Intelligence Dashboard to send the order to the MES system. He sees via an alert that the MES system has received the order and drills down to view the other scheduled orders Manufacturing Yokogawa MES 3 Production Manager collaborates with the operations team to ensure they understand the business importance of the new order 4 Production Manager receives an alert when production of the order has started and drills down to the Yokogawa real-time display of shop floor conditions to monitor production 5 Production Manager receives an alert indicating order completion and reviews the electronic batch record for the order before authorizing product release - 8 -

9 Scenario 4 Raw Material Out of Specification Alert! 1 Production Supervisor logs into his SAP Dashboard and sees all critical KPIs are green and within target levels; he goes to a meeting SAP NETWEAVER Manufacturing Intelligence Dashboard 2 Supervisor returns from his meeting and sees an alert showing production of an order has been aborted 3 Supervisor drills down further to view the live process production status via a Yokogawa iview Manufacturing Yokogawa MES 4 Supervisor collaborates with the operations team and learns the ingredients failed to fully react. The team determines a raw material was contaminated 5 Supervisor instructs the raw material be isolated, alternatives used for scheduled production and has purchasing contact the supplier - 9 -

10 Other SAP Business Solutions Manufacturing Planning Manufacturing Execution Enterprise Asset Management Quality Management Environmental Health & Safety Yokogawa Partner Solution BW How SAP and Yokogawa Enable Closed Loop Operations SAP NETWEAVER SAP Mfg and Yokogawa link real-time plant events to enterprise Manufacturing Intelligence Dashboards Yokogawa uses XI to deliver real-time alerts & drill downs to SAP Manufacturing Intelligence Dashboard Manufacturing Visibility SAP and Yokogawa use XI to exchange ISA-95/B2MML production schedule and production performance messages to integrate the Yokogawa controlled manufacturing shop floor with the SAP managed business processes Yokogawa delivers real-time mfg info to SAP BW for sophisticated decision support/reports

11 Yokogawa/SAP Integration

12 Overview The Yokogawa MES and ERP integration platform Standards based data exchange ISA-95/B2MML Web Services Basis for expansion to standards based ERP systems Exaquantum PIMS is the base platform Capabilities Production schedules Production Performances SAP alert and KPI notifications

13 MDX Architecture ERP, MES, APS

14 Production Management

15 MDX & SAP Capabilities Production schedule Batch Continuous Non-traditional schedule uses are possible Production Performance Any result or status message to an ERP or MES system Batch, production, change over, time basis daily/shift/hour, sample data SAP alert and KPI notification Real Time Displays within SAPs NetWeaver Portal Single sign-on iview URL Integration Links to existing applications iviews Native NetWeaver views developed explicitly for the Enterprise Portal

16 Data Flows for Batch Processes Other Vendors Web Service Download Web Service runs on a Web Server Exaquantum/Batch MSMQ Client MSMQ B2MML Production Performance B2MML Production Schedule Web Service Data Mapping Schedule Files Electronic Batch Record (copy of Control Recipe) Report EQ Tags & Function Blocks HIS.dt File Creation CENTUM VP Batch.dt Schedule File Batch Schedule Client Application configuration: Data in production schedule available as batch formula data SEBOL logic uses formula data as needed Batch Management Exaopc FCS Batch (Control Recipe) OPC Batch SEBOL OPC DA, A&E CS 3000/VP Function Blocks CENTUM VP Function Blocks

17 Data Flows for Continuous Processes Other Vendors Web Service Download Web Service runs on a Web Server Exaquantum or Exaquantum/Batch MSMQ Client MSMQ B2MML Production Performance B2MML Production Schedule Web Service Data Mapping Schedule Data Production Record (optional) Custom Batch Data Collection Report HIS, Exaopc, Generic PC Handshake used to avoid overwriting data OPC Schedule Client OPC DA EQ Tags & Function Blocks ExaPilot CENTUM VP Tag.DataItem CENTUM VP Function Block Tag.DataItem Other Vendor s PCS, PLC, OPC DA, A&E

18 CS 3000, CENTUM VP and Exaquantum Displays in SAP NetWeaver Business Portal

19 Yokogawa Generated Alert Notifications Yokogawa Generated KPI values Main Next

20 Exaquantum/Batch in the NetWeaver Portal

21 SAP Screen: Change Process Order

22 Enterprise Portal Native iviews

23 Customer Benefits Integration of MES & ERP systems to break down information silos within the plant Receive Real Time KPIs Receive Alerts View Production screens Issue orders, setpoints, etc. View manufacturing reports Enables management by exception

24 Implementation Considerations

25 Implementation Considerations Scenario Definition Data Integration Data Mapping/Translation Data Exchange MDX / XI SAP ODA (OPC Interface) View Integration Portal versus Power Application URL versus iviews SAP License Requirements Must bring together MES and ERP parties for a successful solution

26 SAP Versions Supporting ISA-95 Solution Package Production Schedule & Requires NetWeaver XI 3.0 (1) Performance Schemas Supported Maintenance Requests, Work Orders, Response Supported mysap ERP 2005 Yes (2) Yes Yes mysap ERP 2004 Yes (2) Yes Yes R/3 4.7 Yes (3) Yes Only Maintenance Requests R/3 4.6C Yes (3) Yes Only Maintenance Requests 1 NetWeaver XI 3.0 required for message orchestration 2 mysap ERP includes NetWeaver XI Requires NetWeaver XI 3.0 and User licenses

27 ISA-95 & ERP Integration Summary Provides real-time bidirectional information to the business Closes the loop between business & production processes A standards based approach to ERP integration Flexible implementation approach Faster and easier to implement/modify as compared to proprietary techniques

28 Yokogawa Marex Limited