Process Messages for Automation and Efficiency. Robbie Norris Jean Liu

Transcription

1 [ Process Messages for Automation and Efficiency Robbie Norris Jean Liu

2 [ Eastman Chemical A global manufacturer of chemicals, plastics and fibers headquartered in Kingsport, Tennessee Approximately 10,000 employees and over 20 manufacturing sites around the globe A company dedicated to environmental stewardship, social responsibility and economic growth 2011 Sales revenue of $7.2 billion Traded on the NYSE under symbol EMN 2

3 [ Highly integrated, diverse businesses Coatings, Adhesives, Specialty Polymers & Inks Specialty Plastics Fibers Performance Chemicals & Intermediates 3

4 [ Where our products are found Packaging 17% Tobacco 16% Building & construction 15% Consumer goods 9% Health & wellness 9% Other 2% Energy, fuels & water 3% Electronics 3% Agriculture 3% Transportation 7% Industrial chemicals 8% Durable goods 8% 4

5 [ Learning Points Process Message 101 Capabilities of a Process Message Possible Scenarios for using a Process Message 5

6 [ Manufacturing Overview Process Planning Process Management Process Control Execution Process Order Control Recipe Process Control System Other Destinations Process Messages PI Sheet 6

7 [ What is a Process Message Communication structure that is used to transfer process data from process control SAP delivers standard messages out of box Goods Issue Posting Goods Receipt Posting Batch Creation Phase Confirmation And many more! Fully Customizable Copy and modify standard messages Create your own messages to do anything (not just data from a PCS) 7

8 [ What is a Process Message cont d Elements of the Process Message Process Message Category Process Message Destination Characteristics Destinations of a process message 1 - Other SAP components (i.e. function module) 2 - User-defined ABAP table 3 - Users of the SAPoffice mail system 4 - External function modules 8

9 [ Why Use a Process Message? Volume of data No manual entry or limited entry Buffering capability Monitoring capability Order of manufacturing process may not be what SAP expects Good way to avoid or re-process record locks Avoid commit in update tasks 9

10 [ Creating a Process Message Process operator on a PCS system Automated Control system Semi-Automatically with SAP OPC/ODA Transaction C057 Within an ABAP Program BAPI_PROCESS_MESSAGE_CREATEMLT 10

11 [ Process Message Monitoring Transaction C054 Select by criteria Plant Date/Time Sender Process Order Message Category Statuses Message Processing in the Monitor Change Message Send a Message Delete Message 11

12 [ Examples of Process Message Configuration The Message Destination Production Plannning for Process Industries ->Process Management ->Process Messages -> Process Message Destinations 12

13 [ Examples of Process Message Configuration - cont d Message Destination Fields 13

14 [ Examples of Process Message Configuration - cont d The Process Message Category The Process Message Category Characteristics Production Plannning for Process Industries ->Process Management ->Process Messages -> Define and Set Up Process Message Categories 14

15 [ Examples of Process Message Configuration - cont d Assignment of Characteristics to the Destination Fields 15

16 [ Control Recipes Process Instructions built into the process order Define processes to be executed by a process operator OR executed by a process control system Process Order must be configured for sending Sent from SAP to a PCS in a process message like structure Comparison to a process message Sent from SAP -> PCS on release of process order Monitored with transaction CO53 instead of CO54 (Process Messages) Configured in customizing similarly to a PM 16

17 [ Control Recipe Monitoring Transaction C053 Select by criteria Plant Date/Time Destination Process Order Statuses Individual Recipe Display 17

18 [ Eastman Architecture ODA Interface SAP Process Messages Control Recipes Process Messages PSRLink OSI Software SAP OPC PIMS (Eastman Custom Apps) PI DCS 18

19 [ SAP Delivered Process Messages PI_PROD Posting a Goods Receipt 101 Movement Scenarios used by Eastman Manual trigger Automated trigger Timer Event Based 19

20 [ SAP Delivered Process Messages cont d PI-CONS Goods Issue Posting 261Movement Scenario Used if backflushing is not set up on a process order Triggered automatically and manually 20

21 [ SAP Delivered Process Messages cont d PI-PHCONS Confirmation of Phases 261Movement Scenario Triggers backflushing on the process order Triggered automatically and manually 21

22 [ SAP Delivered Process Messages cont d Other Frequently Used Messages PI_BT_CR Batch Creation PI_ORDCO Confirms Order PI_PHST Set Status of the Phase PI_CRST Set Status of the Control Recipe PI_BT_CL Assign Values to Batch Characteristics 22

23 [ Business Cases for Eastman Customized Process Messages Used in Business Areas Quality Management Inventory Management Logistics Waste Disposals Advantages Asynchronous updates Ability to reprocess the errors Communication with Remote Systems 23

24 [ Eastman Customized Process Messages - QM Quality Management YQA01 - Create Inspection Lot YBATCHCK - Adjust Batch status to Blocked if quality is out of Specification YPKB - Create the Parent-Child relationship between a Bulk Material and a Packaged Material YMD3 Update quality of the child package material 24

25 [ Eastman Customized Process Messages QM Quality Management YQA01 - Create Inspection Lot Scenario - Create In-process Inspection Lots Create Inspection lot for lab analysis prior to Report Production 25

26 [ Eastman Customized Process Messages - QM Quality Management YBATCHCK - Adjust Batch status to Blocked if quality is out of Specification Scenario - Re-evaluate the Batch quality and change Batch Stock status accordingly after silo transfer 26

27 [ Eastman Customized Process Messages - QM Quality Management YPKB - Create the Parent-Child relationship between a Bulk Material and a Packaged Material YMD3 triggered by UD follow up to copy result to child packages Scenario - Lab tests not complete prior to the repack process 27

28 [ Eastman Customized Process Messages - IM Inventory Management YGMNCHG YPRODADJ YINVADJ YXFER YPRD_NPO - Change Material Number - Adjust production against Process Order - Adjust Inventory Quantity - Transfer inventory from one material to another material, from one batch to another batch or from one location to another location. - Create Process Order and Post Production 28

29 [ Eastman Customized Process Messages IM Inventory Management YGMNCHG - Change Material Number Scenario - Downgrade a Material Move inventory out of blocked stock if needed (343) Change Material number while in unrestricted Stock(309) Move new material into blocked stock(344) 29

30 [ Eastman Customized Process Messages - IM Inventory Management YPRODADJ - Adjust production against Process Order Scenario - Re-weigh a package due to damage Calculate the quantity changed Adjust quantity against the original process order Achieve accurate Product Costing 30

31 [ Eastman Customized Process Messages - IM Inventory Management YINVADJ - Adjust tank or silo inventory Scenario - Estimate Back flush consumption Conduct scheduled physical inventory Determine which movement type to use (911 or 912) 31

32 [ Eastman Customized Process Messages - IM Inventory Management YXFER Create Material Movements Scenario Change Material Change Batch Change Storage Location Report by-product Report consumption Report production Goods Issue for Cost Center 32

33 [ Eastman Customized Process Messages - IM Inventory Management YPRD_NPO Create Process Order and Post Production Scenario At the end of a production run, create Process Order and report production for a heel or waste. 33

34 [ Eastman Customized Process Messages Logistics Logistics Truck and Railcar YRAILXFR Transfer inventory from Tank Batch to Shipping Batch for shipment YRAILADJ - Adjust the actual shipping weight YRAILWE Perform weight entry of a Delivery Note 34

35 [ Eastman Customized Process Messages - Logistics Logistics YRAILXFR - Transfer inventory from Tank Batch to Shipping Batch for shipment Scenario - Use movement type 311 Triggered from SAP application Uses process message so errors can be investigated at a later date 35

36 [ Eastman Customized Process Messages - Logistics Logistics YRAILADJ - Adjust railcar shipping weight Scenario - The original silo-torailcar transfer quantity was estimated. The new quantity is the actual scale weight for the railcar batch. Determine which movement type to use (911 or 912) 36

37 [ Eastman Customized Process Messages - Logistics Logistics YRAILWE Perform Weight Entry of the Delivery Note Scenario - Railcar operator responsible for entering the weight. Shipping office personnel responsible for correcting issues with Delivery Note 37

38 [ Eastman Customized Process Messages Waste Disposal Semi-Automatic Drum Disposal YTXDRWT YTXDRLD Scenario - Drum Weigh - Drum Load Trigger by SAP OPC on Drum conveyor Integrates SAP ODA with Process Messages SAP subscribes to certain drum DCS items/tags of a DA server Value change event of an drum DCS item/tag automatically creates process messages 38

39 [ Drum Loading Process 39

40 [ Eastman Customized Process Messages Remote Communication Messages from SAP to Remote Systems OSI_COMM Destination type 2 Tank or Silo Inventory updates Quality Updates after Automated Usage Decision Material Movements for Trending 40

41 [ Best Practices Use SAP delivered process messages whenever possible Production staff should monitor messages daily Buffering capability should exist on the remote system Use automated re-send capability when required 41

42 [ Key Learnings Process messages are structures of data passed to SAP Control Recipes are process instructions sent to a PCS SAP delivered process messages perform many common functions Copy or create process messages to meet your business processes 42

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