SAP s MII Real World Manufacturing Applications
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- Horatio Osborne
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1 SAP s MII Real World Manufacturing Applications
2 Topics Introduction to MII/Seeit Solutions Real World MII Applications Efficiency MII OEE Quality MII Quality & SPC Utilities Energy Mgmt Shop Floor Labor Tracking MII Labor Tracking Mobile Worker MII Handheld HAACP Why Seeit Solutions as Your Partner? Discussion and Questions
3 Introductions: SeeIT Solutions SeeIT Solutions 100% focused on SAP Plant Floor to ERP solutions From I/O & PLC s to SAP ERP Modules SAP Authorized Services Partner SAP MII FET certified Experience with Lighthammer (now MII) since 2001 with many installations Customers include PepsiCo., Anheuser Busch, MillerCoors, Sargento, Gallo, Nestle, Lockheed Martin, Molex, Metalcraft, Whirlpool, Certainteed, Kraft Foods Focused on solutions that track efficiency, improve quality, and order execution while reducing cost and risk SeeIT MII Factory Event Database Integration experience with Plant Floor Solutions: Rockwell, Siemens, GE Fanuc, Infinity QS, Maximo, Kronos Time and Attendance, Informance/OEE, Hand held/mobile deployments
4 Current Status
5 Excel and Paper Analysis
6 MII = Manufacturing Integration and Intelligence EMO ERP/MRP Automated ERP transactions Automated processes ERP visibility Composite metrics Service enablement SAP MII Operational Excellence TPM/Lean Manufacturing Continuous Improvement Six Sigma Manufacturing Integration Manufacturing Intelligence
7 Real World Applications Beverage Manufacturer Global Electronics Manufacturer Defense Contractor Missile Manufacturer Food Processor Metal Fabrication & Lawn Mower Manufacturer Building Products Manufacturer
8 Real World Application - Beverage Manufacturer Business Drivers Line Efficiency and Manufacturing Reporting/Automatic Production Confirmations Results Tight SAP ERP integration using MII Efficiency by Plant, Line, Asset, Product, Lot Receiving User Interface Simplified GUI Material Flow and Material Efficiency Reporting Finished Goods Confirmation Reporting Automatic Production Confirmations into SAP ERP Screens
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15 Real World Applications Beverage Manufacturer Global Electronics Manufacturer Defense Contractor Missile Manufacturer Food Processor Metal Fabrication & Lawn Mower Manufacturer Building Products Manufacturer
16 Molex Global Electronics Manufacturer MII chosen as global standard for Shopfloor and MES capability Utilize a standard and simple interface for all requirements between shopfloor and SAP ERP Single User interface for manufacturing employees (confirmations, schedule, etc.) Kronos MII Interface (Seeit Developed) Provide local survivability in cases where SAP is down globally Currently using MII for Shopfloor SAP interactions (confirmations, schedule, etc) Productivity and Efficiency monitoring including Machine OEE Handheld RF interface to SAP Interface SAP to Kronos for labor and work order activities Overhead Scoreboard Displays in Plant
17 Molex Shopfloor Information System Objectives Allow for SAP Production Order Confirmations utilizing actual machine data (quantities, scrap, downtime, etc.) Enable the ability to gather machine events details for production and downtime occurrences linked by production order, shift, date, operator, etc. Increased Efficiency and Productivity by providing visual feedback to operators and managers about current operations based on real time actual data Increase visibility to Shopfloor landscape utilizing actual machine data (runtimes, production order numbers, production rates, actual vs. plan, etc.) Present a view to machine and tool planning for use on the Shopfloor Allow for analysis of machine downtime Data needed to be captured by machine centre, tool, operator, shift, and date
18 Plant Overview
19 Department Overview
20 Machine Overview
21 Machine Downtime Details
22 Post Production Confirmation to SAP
23 Post Machine Downtime and Reasons to SAP
24 Production Order Details
25 Production Plan Overview - Daily
26 Production Plan Overview - Weekly
27 Shift Production Report
28 Report Top 10 Stopped Machines
29 Report Machine Top 10 Downtime Reasons
30 Report Downtime Events over 15 Minutes
31 Handheld - Main Menu
32 Handheld Post Production Confirmation to SAP
33 Handheld Downtime Confirmation to SAP
34 Real World Applications Beverage Manufacturer Global Electronics Manufacturer Defense Contractor Missile Manufacturer Food Processor Metal Fabrication & Lawn Mower Manufacturer Building Products Manufacturer
35 Lockheed Martin Defense/Aerospace Manufacturer MII chosen as Shopfloor SPC System for MFC Utilize a standard and simple interface for machine operators and quality professionals in the plant Single User interface for shopfloor employees (confirmations, inspections, etc.) QM interface & CMM interface Provide local survivability in cases where SAP is down globally Currently using MII for Shopfloor SAP interactions (inspections, qc data, etc) CMM Interface SAP QM Interface
36 Inspection Results Acceptance and Posting to SAP
37 Production Order Entry
38 Characteristic Selection
39 SPC Display
40 Result Comment Entry
41 Characteristic Data Details
42 Real World Applications Beverage Manufacturer Global Electronics Manufacturer Defense Contractor Missile Manufacturer Building Products Manufacturer Metal Fabrication & Lawn Mower Manufacturer Food Processor
43 Certainteed Building Products Shop floor reporting/information system Quality focused project Lost production reporting Production reporting: Safety, VOC, Inventory, Production Targets and actual vs. targets recorded Historian Interface (Real-time and Historical data) Factory Event Interface users over many plants
44 Building Products Company Example
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51 Real World Applications Beverage Manufacturer Global Electronics Manufacturer Defense Contractor Missile Manufacturer Building Products Manufacturer Food Processor Metal Fabrication & Lawn Mower Manufacturer
52 Food & Beverage Processing Shop floor information system Tracking asset utilization-oee Historian Interface (Real-time and Historical data) SeeIT Factory Event Database (Downtime and Scrap) Scoreboard/Overhead Factory Displays Tight SAP integration using MII 100 s of assets per plant-many plants back to central ERP
53 Packaging Operator Examples
54 Packaging Performance Details
55 Packaging Machine Details
56 Packaging Quality Dashboard
57 Overhead Scoreboard Display Example From a Food Processing Company Machine Status Current Downtime Information Production rates Waste/Quality Panel Production Metrics Tip of the Day Scroll
58 Food Processor Lunchroom Scoreboard
59 Food Processor Management Dashboard
60 SPC Net Weight Dashboard
61 Boilers Chillers HVAC Air Comp. Electric Power Gas This place gives me a headache Asset Management Maintenance Environmental Management Energy Lighting Control Management
62 Digital Dashboards
63 Real World Applications Beverage Manufacturer Global Electronics Manufacturer Defense Contractor Missile Manufacturer Building Products Manufacturer Food Processor Metal Fabrication & Lawn Mower Manufacturer
64 Metalcraft Industrial Lawn Mowers/Parts Shop floor job tracking Operator User Interface for labor/job tracking Recording steps, actual vs. planned Automatic Updates to ERP for actual by product, crew, 800+ Users, multi-plant
65 Interfaces SAP HR, PP, MM & IM modules 3 rd Party Dynamic Nesting software Passing Work Order data Receipt of transactional data Automatic Goods Movement (Issue) of material 3 rd Party Label Printing software Warranty Tracking database (internal)
66 Features Real-time Inventory & Work Order/Operation updates into SAP Time clock collection Crew clocking management/collection SAP database validation PP - Work order data HR - Employee & Work Schedule master files MM - Material master
67 Main Operator Menu
68 Operator Clock In Secure scanning of employee badges for ALL transactions Time Clock functionality
69 Job On/Off Work order data scanned from shop packet Reporting of good & scrap qtys Request to print a travel ticket
70 Supervisor Functionality Employee data displayed based on Supervisor/Employee role assignment in SAP HR Ability to review data transacted by each employee Make adjustments to quantities reported Make adjustments to transaction times Audit tracking of changes Traffic light feature indicating errors Rounding rules based on employee Work Schedule in SAP HR Entry of employee Absences Employee Time Clock data & absences passed to SAP HR CATS Mass employee approval of transactions into SAP HR, PP & IM Labor Efficiency dashboard
71 Supervisor Panel
72 Supervisor Screens Discrepancies indicated by radio lights Time & Attendance review and Absence entry
73 Labor Efficiency Dashboard Multiple reporting selections Date ranges By WO, Shift, Work Center, Cost Center, Employee
74 Closure of Examples Introduction to MII/Seeit Solutions Real World MII Applications Efficiency MII OEE Quality MII Quality Utilities Shop Floor Labor Tracking MII Labor Tracking Mobile Worker HAACP Discussion and Questions
75 Why Choose SeeIT Solutions as Your MII Partner? Experience with product-7+ years Experience with MII across many diverse applications SAP Authorized Services Partner MII Field Enabled Training (FET) certification Getting Started Process for MII MII Readiness Survey Pathfinder Justify/Sell Your Project MII Configured Solutions Understand Shopfloor Information flow (PLC to ERP) US Based development team
76 Seeit Solutions MI Applications? Partial listing of some of Manufacturing Intelligence (MI) application templates and interfaces that Seeit has developed: mi Performance Metrics - configurable performance metrics enabled by a Performance Event Database mi Workforce - directional interface between Kronos Workforce Timekeeper & Activities to SAP PP/PP-PI, & HR mi Mobile - use mobile devices to transact to and from SAP ERP and receive real-time reports mi Touchscreen - a shop-floor application designed by the user with direct updates and interaction with SAP ERP mi Labor Tracker - an application that provides transactions to update your SAP HR and CATS mi SPC Shopfloor - shop-floor SPC application presenting real-time Quality and Attribute data collection & charting with updates to SAP QM and PP/PP-PI mi Intelligent Historian Connect - interface data to SAP ERP from your Process Historian mi Production Scheduling Board - a shop-floor scheduling updated from SAP planned orders or APO mi Scoreboards - an application designed to drive large overhead monitors presenting KPIs from SAP or other plant based systems Leveraging our 20 Years Experience integrating ERP to the Plant
77 Questions
78 Contact Information Kevin Bader Partner SeeIT Solutions LLC T C (262) (847) [email protected] Brian Kuchinski SeeIT Solutions LLC T C (847) (847) Sr. Program Manager
79 POWER 100M LNK/ACT FDX 1 PowerConnect Data Collection from I/O to SAP ERP
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