SAP Manufacturing Integration and Intelligence at Dunn-Edwards. Brij Mathur IT Director May 2011

Transcription

1 SAP Manufacturing Integration and Intelligence at Dunn-Edwards Brij Mathur IT Director May 2011

2 What We ll Cover Introducing Dunn-Edwards Assessing our goals, surveying our landscape Understanding SAP MII Leveraging SAP MII batch manufacturing templates Improving quality management and plant maintenance using SAP MII Integrating SAP and plant systems using SAP MII plant connectivity Sharing lessons learned and seeing SAP MII at work Wrap-up 2

3 Dunn-Edwards Overview Founded in 1925 Headquartered in Los Angeles, CA Employee owned Operates more than 100 retail outlets in Arizona, California, Nevada, New Mexico, and Texas Serves both the professional painter and the consumer market Slogan: The #1 Choice of Painting Professionals 3

4 Our Manufacturing Issues and Goals Issues Paper-based manual processes Uncontrolled processes, e.g., tribal knowledge Production bottlenecks No real-time visibility First Pass rates not at desired level Limited production facilities Inefficient processes Goals Automated processes, no paper System-controlled processes Integrate end-to-end Real real-time visibility Improve First Pass percentage Increase manufacturing production by significant margin 4

5 Considering Our New Facility and Choosing the Software Build a new state-of-the-art green field manufacturing facility Located in Phoenix, AZ Choose integration and visualization software SAP MII (Manufacturing Integration & Intelligence) SAP PCo (Plant Connectivity) Resulting in: Higher productivity for shop floor personnel Continuous improvement in processes and performance Faster time to value Quick development timeframe 5

6 Surveying Our System Landscape SCADA - PcVue Controls ISaGRAF (Rockwell Automation) Formulations Transform & Interface Recipe Management Sales and Operations Planning MRP Schedule & Process Orders Product Costing Transform & Interface Simplify User Data Entry Execute Process Order Send Data Back Process Controllers SAP PCo OPC PcVue OPC

7 Typical SAP MII Application Areas

8 Using SAP Batch Manufacturing Templates Collection of best practice templates for SAP MII Prebuilt, plant and role-specific composites Free of cost, downloadable from SAP Service Marketplace Delivered by SAP AG from February 2010 Why did we use the SAP batch manufacturing templates? Reduced development Faster time to testing Low risk Proven templates that work Free-of-charge 8

9 Work Instruction and Order List, SAP MII Batch Manufacturing Template Template: Date parameters are entered and executed to see schedule 9

10 Using SAP MII for Quality Management Combined two SAP Batch Manufacturing templates into one Results Recording Qualitative Quantitative Usage Decision Notify Chemist via Material adjustment Generate Transfer Requirements (TRs) in SAP ECC Post instructions to Shop Floor system History of results recording Send the batch back to Manufacturing 10

11 Using SAP MII for Plant Maintenance Simplified Web-based user interface for non-sap users Less complexity Only necessary data is displayed to user Only required data is entered by user Integrated to SAP ECC on back end Inherent, uncomplicated integration Hidden from user SAP MII logic decides what type of ticket and its importance before creating in SAP ECC Maintenance Manager supervises all tickets in SAP ECC 11

12 SAP Plant Connectivity Plant Connectivity (PCo) is the name of SAP s next-generation, high-performance manufacturing plant connectivity software; enables real-time, event-driven integration between plant & enterprise systems Designed to: Provide unsolicited real-time event notification capabilities from plant manufacturing systems to SAP applications Enable query execution capabilities against plant manufacturing systems (i.e., UDS-style queries, etc.) Be a highly extensible plant connectivity infrastructure on which to build manufacturing applications Provides the connectivity infrastructure enabling robust, high-performance integration between SAP and Plant Systems 12

13 Lessons Learned Integrate the manufacturing engineering and IT teams Held joint design sessions Agreements and approvals required from all sides on requirements, design, testing, implementation, cutover, and on-going support Ensure integrated plant across all areas Building construction Software implementation Systems integration Infrastructure and network segmentation for process controls Held weekly timeline and critical path meeting with architects, general contractor, key sub-contractors Testing 13

14 Lessons Learned (cont.) Test Cycles Cycle 1 Cycle 2 Cycle 3 Cycle 4 Business Objective Description SAP ERP functionality test SAP ERP with PcVue test Water Run Paint Run Test PV5, SAP ECC & SAP MII development & configuration Integration Test PV5, SAP ECC, SAP MII & PcVue Integration Test PV5, SAP ECC, SAP MII, PcVue & IsaGraf Production Run of PV5, SAP ECC, SAP MII, PcVue & ISaGRAF Schematic Product Vision ECC MII Product Vision ECC MII PcVue Product Vision ECC MII PcVue IsaGraf Comments In QA environment 1. In QA environment, testing 1 production line 2. Partial functionality in PcVue, from the integrated testing perspective 1. In QA environment, testing all 6 production lines 2. Full PcVue functionality In Production environment Start Date 10/4/ /18/ /15/2010 1/10/2011

15 Your Turn! How to contact me: Brij Mathur 15