SAP xApp Manufacturing Intelligence & Integration

Version 1.0 June08

Prepared By
Vijaya Vardhan Reddy (SAP Practice)

2005 KPIT Cummins Infosystems Limited

We value our relationship

Content
xMII:
Introduction Overview Benefit Usage and Roadmap Business View Sizing

Slide No.: 2

20 September 2012

Presenter: Vijaya Vardhan Reddy

Introduction

Russ Fadel, ex-CEO and co-founder of Lighthammer Currently, VP ASM MANUFACTURING 25 years in all aspects of Manufacturing Shop Floor Automation (SFA, MES, etc) In 2005, SAP acquired Lighthammer OBJECTIVE:

Provide information necessary to understand ASM Manufacturings positioning of xMII and XI for Manufacturing integration

Slide No.: 3

20 September 2012

Presenter: Vijaya Vardhan Reddy

The Current State of Manufacturing - Disconnected

Enterprise
Disparity of Systems and Data A typical manufacturing plant will have between 10 and 50 shop floor automation (SFA) systems A multi-site manufacturer will have between 40 and 700 SFA systems across its enterprise typically running in a disconnected fashion

DISCONNEC T

Factory

Less than 1% of respondents indicated that manufacturing data is automatically integrated with ERP with no manual intervention
Managing Automation and AMR Research September 2005, Customer Survey
Slide No.: 4 20 September 2012 Presenter: Vijaya Vardhan Reddy

DISCONNEC T

Impact on Manufacturing Performance

Cant Manage Performance Time Lag between event occurring and actionable response is 24 hours to a month

MESA Metrics, Oct 2006

Reactive Performance Management

OPERATIONS

Redundancy and Multiple Data Touch Points Plant Execution not connected to Business Workflow

IT

Ballooning IT Costs SC Planning (76%) Inbound Materials(67%) Enterprise PLM (56%) Factory Floor Systems(70%)
Aberdeen Group, 2006

Cant Respond Effectively

PRODUCTION

Packaged MES addresses only 20%-30% of functional requirements

MESA Metrics, Oct 2006

Slide No.: 5

20 September 2012

Presenter: Vijaya Vardhan Reddy

Adaptive Manufacturing: The SAP Perspective . . .

Adaptive manufacturing is the ability of a factory to replenish the supply chain profitably while dynamically responding to unpredictable change To become adaptive manufacturers must embrace manufacturing synchronization and manufacturing excellence to become adaptive

Slide No.: 6

20 September 2012

Presenter: Vijaya Vardhan Reddy

Why Must Manufacturers Be Adaptive?

To be adaptive, companies need capabilities for:

Enterprise
Manufacturing operations: An integrated ERP solution
for managing manufacturing with workflows that enable closed-loop operations

Manufacturing integration: A manufacturing integration

platform to synchronize manufacturing processes and people with enterprise processes

Factory

Manufacturing intelligence: Real-time, actionable

analytics and decision support for production personnel so that they can deliver on their performance goals Visibility Responsiveness Performance

Slide No.: 7

20 September 2012

Presenter: Vijaya Vardhan Reddy

SAP xMII offers these Core Functions/Services to enable Manufacturing Integration and Intelligence MANUFACTURING INTELLIGENCE
Visualization Services Charts, grids, tickers, UI controls Dashboard components Metrics/Alerts KPIs and Alerts Analytic Services SPC/SQC (Six Sigma) analyses Statistical and other mathematical analyses

MANUFACTURING INTEGRATION
Data Services Bi-directional data access Metadata browsing XML-based data abstraction Connectors to external systems Business Logic Services Logic Integration services Notification services Calculation and data transformation MFG Standards implementation
Web Services

SAP xMII Visualization

Mfg. Intelligence Business Logic Services Analytic s

Mfg. Integration S95/B2MM L Standard Other Standar ds Core Mfg Services

Web Services
All services exposed as web services Includes user-defined composite services

Alerts

KPI

Manufacturing Intelligence

Manufacturing Integration

Data Services

Connectors

Slide No.: 8

20 September 2012

Presenter: Vijaya Vardhan Reddy

Manufacturing integration Pre-xMII, Pre-XI

SAP

Corporate

Enterprise Applications mySAP ERP/4.6c/4.7

Competitor

SAP BC

EAI (BC, IBM, Biztalk)

EAI

Plant Plant Application Integration (3rd Party, Biztalk, IBM, custom, etc)

Plant Level Functions Store and Forward Disconnected Operation Master data caching

Slide No.: 9

20 September 2012

Presenter: Vijaya Vardhan Reddy

Manufacturing integration Pre-xMII

SAP

Corporate

Enterprise Applications mySAP ERP/4.6c/4.7

Competitor

SAP XI

EAI

Plant Plant Application Integration (3rd Party, Biztalk, IBM, custom, etc) Plant Level Functions Store and Forward Disconnected Operation Master data caching

Slide No.: 10

20 September 2012

Presenter: Vijaya Vardhan Reddy

New Manufacturing Integration xMII

SAP

Corporate

Enterprise Applications

Competitor

mySAP ERP/4.6c/4.7

End-to-End Custody

SAP XI

Plant

Plant Level Functions

SAP xMII

Store and Forward Disconnected Operation Master data caching SFA Connectivity End-to-end monitoring Local UI

Slide No.: 11

20 September 2012

Presenter: Vijaya Vardhan Reddy

SAP xMII in a Single Plant/Region Architecture Company

Plant
R3, my SAP ERP SAP NetWeaver

SAP xMII

Slide No.: 12

20 September 2012

Presenter: Vijaya Vardhan Reddy

SAP xMII Enterprise Architecture

SAP xMII in a Multi-Plant Context
Plants

Corp Server

R3/mySAP ERP SAP NetWeaver

SAP xMII

Corp xMII

SAP xMII

SAP xMII

SAP xMII

Slide No.: 13

20 September 2012

Presenter: Vijaya Vardhan Reddy

Maximize Returns from your Manufacturing Assets and Systems with SAP xMII.
SAP xMII Enablers
Adaptive Manufacturing Manufacturing Operations
(SAP ERP)

Manufacturing Levers
Improved Order Fill Rates & On-Time Shipments improves Customer Sat. Higher Quality and Throughput Extend Quality Metrics to Customers Higher Performance and Productivity Per Employee, per Asset, per Plant

Financial Objectives

Revenues Profits

Manufacturing Excellence

Manuf. Synchronization

Minimize Reject, Rework, Overtime & Exception Resolution Costs & Waste Lower Quality and Compliance related Costs and Minimize Penalties Improve Asset Utilization (OEE/ROA) ->Benchmarking Continuously improve Processes (Six Sigma, First Time Right) Better adherence to Budgets and Cost Targets Eliminate redundant MES to ERP Manual Data Entry Costs

Operating Costs Increase your ROI on your Manuf. Assets & Systems Invested Capital Fixed Capital

SAP xMII

Convert Excess Inventory into Cash Flow thru Better Visibility Lower Total-Cost-of-Ownership (TCO) on your manufacturing infrastructure Faster time-to-value on SAP ERP to Plant Systems Integration Rationalize Underperforming Assets and Plants

Working Capital

Manufacturing Integration

Manufacturing Intelligence

Slide No.: 14

20 September 2012

Presenter: Vijaya Vardhan Reddy

SAP xApp Manufacturing Integration and Intelligence (xMII)

The SAP xApp Manufacturing Integration and Intelligence (xMII) is a packaged composite application that delivers:
Manufacturing Intelligence: Real-time six sigma analytics engine that aggregates and delivers unified visualization of events, alerts, KPIs and decision support to production personnel thru role-based dashboards

SAP NETWEAVER
Other SAP Bus. Solu tions Manufacturing Intelligence Dashboards

mySAP ERP SAP Manufacturing mySAP SCM

SAP BI

Manufacturing Intelligence Manufacturing Integration

Manufacturing Integration: A single standards compliant layer enabling SAP ERP connectivity into real-time plant floor apps. (MES, SFA, legacy apps.) to drive plant-toenterprise business process interoperability

SAP xMII enables adaptive manufacturing by synchronizing manufacturing operations with the enterprise to deliver a single version of the truth and drive manufacturing excellence.

MES Manufacturing Execution Systems, EMI Enterprise Manufacturing Intelligence, BW Business Warehouse (from SAP) SFAC Shop Floor Automation & Control, Slide No.: 15 20 September 2012 Presenter: Vijaya Vardhan Reddy

SAP xApp Manufacturing Integration and Intelligence (xMII)

SAP xMII extracts data from SAP ERP and provides real-time visibility and distribution to Plant Floor Systems of:

Enterprise
Other SAP Bus. Solu tions

SAP NETWEAVER
Manufacturing Intelligence Dashboards

SAP xMIIs ability to perform transaction execution into SAP also enables automated, plant-level creation of:

SAP BI

Planned Orders Bills of Material Production & Process Orders Material Inventory Levels Inspection Lots Data Master Recipes Material Details Batch Details Resources & Functional

SAP Manufacturing (mySAP ERP)

XI SAP xMII Manufacturing Intelligence Manufacturing Integration

Production Confirmations Process Messages Material Receipts Material Consumptions Material transfers Inspection results recording Quality Notifications Batch Characteristic recording Work Orders & results recording Maintenance Notifications

Slide No.: 16

20 September 2012

Presenter: Vijaya Vardhan Reddy

Manufacturing Excellence and Synchronization with xMII

mySAP Business Suite

mySAP ERP mySAP CRM mySAP SRM mySAP SCM mySAP PLM

BAPIs IDOCs- RFCs

SAP xMII

Java Connector / Web Services / XI

IDOC BAPI BAPI

Visualization Services: Provides visualization objects to build operational user interfaces in SAP xMII or SAP NetWeaver Portal

Business Logic Services: Connect to SAP business suite applications, enforce business processes, model workflow, and schedule tasks

All services exposed as web services

Displays

User-defined composite services

Queries

Data services: Bidirectional data integration extract and aggregate data from different data sources; update data in target systems

Analytic Services: Statistical Process Control (SPC) Statistical Quality Control (SQC) Six Sigma analyses

Connectors

Slide No.: 17

20 September 2012

Presenter: Vijaya Vardhan Reddy

Benefit Usage

2005 KPIT Cummins Infosystems Limited

We value our relationship

SAP xMII for Manufacturing Integration Extensible Service Oriented Architecture

Open, two-way service-based integration

All SAP xMII services accessible via SAP and non-SAP applications

Integrates with the broadest range of manufacturing applications and data sources
Content-focused information delivery: Displays can be delivered via SAP xMIIs Plant Portal, SAP Enterprise Portal, and others

Slide No.: 19

20 September 2012

Presenter: Vijaya Vardhan Reddy

SAP xMII for Manufacturing Integration Extensible Service Oriented Architecture

Designed for Extensibility

Rapid creation of new connectors Open architecture for logic engine enables 3rd party plug-ins

Part of a larger ecosystem

Collaborating with shop floor partners for pre-built integration scenarios and intelligence content as well as connector development Enables the platform for manufacturing-specific services for NetWeaver

Slide No.: 20

20 September 2012

Presenter: Vijaya Vardhan Reddy

SAP xMII Solution Roadmap High Level Objectives

Provide a unification solution for the manufacturing

integration/ analytic solutions currently in the SAP portfolio Deliver a uniform customer experience Open, standards-based integration between systems

Extend KPITs role in manufacturing

Initial focus on integration and intelligence Foundation for future focus in other plant floor application areas

Slide No.: 21

20 September 2012

Presenter: Vijaya Vardhan Reddy

SAP xMII Solution Roadmap High Level Objectives

Enable innovation in our customers businesses

Pre-built/packaged functionality yields competitive parity, while innovation yields competitive advantage Continue to deliver new functionality based on customer input Configurability/flexibility is a fundamental requirement Must enable incremental, high-value implementation

Ensure a smooth migration path for existing Lighthammer and

SAP xMII customers Protect application/content development investment Ongoing application continuity via migration tools and services

Slide No.: 22

20 September 2012

Presenter: Vijaya Vardhan Reddy

SAP xMII Product Roadmap Overview SAP xMII 11.5

Lighthammer CMS Re-branded as SAP xMII 100% Java technology comprehensive localization capabilities new connector framework Integration infrastructure for support of B2MML and most other standards Intelligence analytics and visualization services for dash boarding, decision support, and data entry applications

SAP xMII 11.5

JCO Interface PDF output for reporting PDF document generation Integration Standards based (S95, OAGIS, etc) integration Package. Visual Composer Integration

SAP xMII 12.0

Leverage Web AS capabilities Supportability
Leverage UME for security

Future SAP xMII Releases

Master Data Distribution
Master data/planning data
synchronization to plant Synchronized operational execution data from plant

Integration new core manufacturing services/S95 capabilities XI as the message bus manufacturing performance management with built-in case management system Intelligence integrated GUI page builder SAP xMII iView Builder and Enterprise Portal content

Publish / Consume services into the ESR Integration enhanced real-time collaboration features, links to guided procedures, Mobile Integration Intelligence WebDynpro-based GUI builder aggregation of content in task-focused worksets Connector Dev Framework*
Presenter: Vijaya Vardhan Reddy

Intelligence
Manufacturing Dashboard Integration KPI / Alerts
New SPC/SQC features user limits, asymmetric limits

Slide No.: 23

20 September 2012

Road Map

2005 KPIT Cummins Infosystems Limited

We value our relationship

Original Equipment Manufacturers

OEM
Aircraft Manufacturers
Electrical Equipment Manufacturers Automobile Industry Computers

Slide No.: 25

20 September 2012

Presenter: Vijaya Vardhan Reddy

Car Manufacturing Process

Cutting Edge Technology Stamping Welding

Engine & Gear Box

Foundries

Painting

Final Assembly

Slide No.: 26

20 September 2012

Presenter: Vijaya Vardhan Reddy

Where XMII can be implemented?

At any step of the Process. Stamping: ( for Skoda ) 3 Stamping Factories 14 stamping lines and other Production lines 1300 fabia bodies or 860 secondgeneration Octavia bodies Casting tools ---> Machining centers Ex: Producing stamping dyes for car side plates

Slide No.: 27

20 September 2012

Presenter: Vijaya Vardhan Reddy

xMII Implementation

Production schedule sent from SAP ERP to MES via SAP xMII Quality data reveals excess moisture in the batch, caused by faulty dryer SAP ERP quarantines batch and issues maintenance notification to fix the dryer

Plant Manager sees notification in his Intelligence Dashboard Plant Manager sees alert on his dashboard and drills down for root causes

SAP xMII initiates production on the batch via MES, and monitors progress Quality exception detected in real-time and communicated via SAP xMII

Slide No.: 28

20 September 2012

Presenter: Vijaya Vardhan Reddy

xMII SAP Integration Landscape

...
QM PP PPPI PM MM SD APO

...
Enterprise Portal
xMII iViews Role-based Dashboards Visual Composer

SAP ERP & NW

BAPI RFC IDOCS

IDOC/RFC Adapter

Web Services

Business Warehouse

JCO

iDoc Push

XI

Web Services

SAP xMII

xMII JCO Interface xMII Web Service Interface

xMII iDoc Listener

xMII XI Interface

xMII WAS Interface

xMII Visual Content

xMII KPIs & Alerts

xMII VC Adapter

xMII OLAP Connector

xMII Data Server Interface

UDS

External Web Service

Shop Floor Data Sources

Slide No.: 29

20 September 2012

Presenter: Vijaya Vardhan Reddy

KPIT Road map for Automobile Industry on xMII

Accomplish the following Objectives:

Leverage the existing shop floor infrastructure and manufacturing process and have a complete control on shop floor business process We partner with Auto mfg industries to build scenarios, Demo. Determining crucial points in the current process in order to recommend xMII best practices. Mapping them with xMII enablers Presentation of roadmap with related Operations and Benefits

Slide No.: 30

20 September 2012

Presenter: Vijaya Vardhan Reddy

Business View

2005 KPIT Cummins Infosystems Limited

We value our relationship

Why promote the new Manufacturing Integration Approach

AMR Research Plant Worker Opportunity study for SAP

ERP uplift of $1.25B to $3.1B by increasing penetration/usage of ERP data in plants $1B in Enterprise Manufacturing Intelligence (xMII) $100M+ opportunity for QM, PM and APC/APS

Slide No.: 32

20 September 2012

Presenter: Vijaya Vardhan Reddy

Summary
xMII solves all 4 manufacturing integration scenarios AND extends SAP solution to provide the only End-to-End integration solution for manufatcuring Implementing xMII establishes an KPIT foothold in the manufacturing plant, unlocking the up to $4B plant worker opportunity

Slide No.: 33

20 September 2012

Presenter: Vijaya Vardhan Reddy

What is the Value of Synchronized Manufacturing Operations enabled by SAP xMIIs Manufacturing Integration?

SAP xMII Value Enablers

Business Value / Financial Impact

SAP xMII:

electronically synchronizes enterprise business processes (ERP) and master data with real-time manufacturing processes and

Higher customer satisfaction from

improved responsiveness

Reduced costs, errors and latency

associated with manual data entry of plant data into ERP

systems using pre-built adapters

delivered out-of-the box to deliver a single version of the truth across the enterprise

Rapid time-to-value (ROI)

implementations in as little as 4 weeks

Lower TCO 3 - 5 X on
manufacturing infrastructure integration with SAP ERP

Slide No.: 34

20 September 2012

Presenter: Vijaya Vardhan Reddy

XMII & XI Sizing

2005 KPIT Cummins Infosystems Limited

We value our relationship

PI Sizing Assumption
Case: Sizing Calculations based on the requirements assumed for Oil and Gas industry PI Sizing Assumption : For 14 Plant One PI server allocated. Tier-3 level there will be one XI server 25 GB of data flow per month through the XI server for all the plants. The Average Message Sizing from xMII server is 50KB The number of Message during the peak time is 21000 All the mapping for PI server would be Message Mapping

Slide No.: 36

20 September 2012

Presenter: Vijaya Vardhan Reddy

PI Sizing Assumption
The Adapters we would use most commonly would be SOAP, File, JDBC and Proxies and IDOC

In case of very large messages we would use Java Mapping (SAX Parsing) for Memory Optimizations.

The Peak load will be during 6:30AM to 10:30AM ( as per requirement) where 70% of Active Server hardware will be considered as Redundant Server Size. All the interfaces will be Synchronous.

Slide No.: 37

20 September 2012

Presenter: Vijaya Vardhan Reddy

Landscape of xMII and XI

Landscape w.r.t Disaster recovery
REDUNDANCY SCADA SCADA

SCADA

xMII

xMII

xMII

Main Server Redundancy SAP XI SAP XI

Delhi

Slide No.: 38

20 September 2012

Presenter: Vijaya Vardhan Reddy

PI Sizing Output
Active Server Sizing at 65% of CPU Utilization
Base SAPS Calculation as per QuickSizer 100% 1555

Batch Jobs
Custom Devt. Contingency Total SAPS

20%
30% 20% 170%

311
466.5 311 2644

Redundant Server Sizing at 65% of CPU Utilization 70% of Active Server Size = 1851 SAPS

Slide No.: 39

20 September 2012

Presenter: Vijaya Vardhan Reddy

xMII Sizing Assumption

Every Plant has separate xMII Server All Active connection in xMII server considered as High Activity User Three sizing consideration for xMII Server during Peak hours. 100 70 50 Peak time is 6:30AM to 10:30AM NetWeaver Application server will used to configure xMII 70% of Active Server Sizing will be used as Redundant Server Size

Slide No.: 40

20 September 2012

Presenter: Vijaya Vardhan Reddy

xMII Sizing Output

Active Server Sizing

When Active User is 100
Base SAPS Calculation as per QuickSizer Batch Jobs Custom Devt. Contingency Total SAPS 100% 20% 30% 20% 170% 1555 311 466.5 311 2644

70% of Active server size =779SAPS (Redundant Server Sizing) When Active user is 70
Base SAPS Calculation as per QuickSizer Batch Jobs Custom Devt. Contingency Total SAPS 100% 20% 30% 20% 170% 1555 311 466.5 311 2644

Slide No.: 41

20 September 2012

Presenter: Vijaya Vardhan Reddy

Contd..
70% of Active server size = 582SAPS (Redundant Server Sizing) When Active user is 50
Base SAPS Calculation as per QuickSizer Batch Jobs Custom Devt. Contingency Total SAPS

100%
20% 30% 20% 170%

1555
311 466.5 311 2644

70% of Active server size = 454SAPS(Redundant Server Sizing)

Slide No.: 42

20 September 2012

Presenter: Vijaya Vardhan Reddy

Memory Sizing
Disk Space Estimation

Slide No.: 43

20 September 2012

Presenter: Vijaya Vardhan Reddy

Proposed Solution
SAP R/3

Architecture: Tier III location

SAP XI

Tier II location

SAP xMII

SAP xMII

SAP xMII

SCADA

Slide No.: 44

20 September 2012

Presenter: Vijaya Vardhan Reddy

Thank You

Slide No.: 45

20 September 2012

Presenter: Vijaya Vardhan Reddy