Manufacturing Execution |
Supports the process of capturing actual production information from the shop floor to support production control and costing
processes.
Make-to-Order
Supports customer-order-specific planning and production and is industry-specific. Supports assembly processes for (non-)
configurable products in a repetitive manufacturing environment or the production of (non-) configured products with production
orders. For both processes, the visibility of the customer order is key. This is achieved by using dynamic alerts and order
pegging structures during planning and execution.
Repetitive Manufacturing
Is a rate-based, lean production control system. Based on production and assembly lines, the takt times are used for scheduling.
An optimizer and heuristics are available for model mix planning and line balancing. Continuous input and output are considered
during scheduling. The production runs without any orders for run schedule quantities and production versions. Backflush of
labor and material at reporting points support the lean execution process.
Flow Manufacturing
The customer demand will be pulled through the production process. The key elements of the solution are line design and line
balancing, demand management, line sequencing/model-mix planning, lean execution, backflush, and Kanban management.
Shop Floor Manufacturing
Tracks production orders and controls production. Real-time integration among sales, production planning, and execution improves
the quality and speed of processes. The confirmation of labor and material activities takes place at the operation level.
Milestones, backflushing, and automatic goods receipt can reduce the number of business transactions, and multilevel production
processes can be controlled. The seamless integration to quality management enables quality inspections during production.
Other characteristics are the control of rework, batch tracking, and serial number management.
Lean Manufacturing
Includes the key components of continuous improvement and elimination of waste across the organization.
The key concepts in lean manufacturing are:
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Continuous Flow:Material flows continuously from raw material through to finished product without "waiting" for large batches to be run. Lean
manufacturing addresses the issue of wasting setup time by minimizing setup times, rather than minimizing the number of setups.
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Value Stream:Encompasses all the actions required to bring a physical product through the main manufacturing and business processes from
acceptance of raw materials or components to the delivery of the completed item. The lean enterprise coordinates all supply
lines (internal and external) and links all parts of the value stream so that they converge at the appropriate points in time.
The value stream is mapped out to analyze all steps from start to finish and to redesign them to ensure that they add value
to the final product.
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Value-Added Activities:Activities in the value stream are identified as value-added (VA) or non-value-added (NVA). NVA activities are eliminated
as much as possible. Some NVA activities are unavoidable; these are sometimes referred to as essential NVA activities. Once
mapped, the value stream activities are identified as VA or NVA.
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Pull Production:Production and purchasing activities are based on signals from the follow-on process. That is, materials are supplied when
needed, avoiding unnecessary WIP and speeding the flow of materials through the system. This ensures that work is performed
only when required.
The key elements for lean manufacturing execution are:
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Takt-based Scheduling:
calculates order lead time by multiplying number of takts by takt time. Capacity requirements are created for line resources.
In flow and repetitive, materials remain for the defined takt time of the in-process line. Takt-based scheduling produces
a more exact result than lead time scheduling based on manufacturing order routing explosion.
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Kanban Based Execution:
supports consumption based replenishment. As the material is consumed from the downstream resource and electronic signal,
production Kanban, is sent to the upstream resource to replenish it. The solution also supports Kanban based replenishment
at the supplier level.
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Summarized JIT Calls:
Outbound and Inbound are both supported. Outbound JIT Replenishment is triggered directly in production once a certain quantity
of the material has been consumed. Production itself is given control of the production process which can reduce posting effort.
Inbound JIT is used by suppliers to ship the material in lean quantities based on call-offs from the customer, whose items
represent a pair of date and quantity.
Integrated Product and Process Engineering (iPPE):The integration of engineering design activities with those of manufacturing engineering avoids unnecessary iterations across
functional boundaries and accelerates product development and time-to-market. SAP supports this process by providing a set
of master data that is consistent across the design and manufacturing application areas. iPPE also allows for designing and
balancing production lines.
Process Manufacturing
Supports the plant as a multi-process facility. Resource and recipe management forms the basis for planning and sequencing
batches or production lots. The solver schedules the process order sequence to avoid costs such as cleanout or changeover.
This can be achieved with production campaigns, block planning, or detailed scheduling with a focus on critical resources.
Process orders are used for scheduling, execution, and costing. Process management coordinates the data exchange between the
SAP execution system and connected process control systems. These processes can be documented and evaluated. The seamless
integration with the quality management ensures process control and stability.
Batch Management
Batch management fulfills the requirements of the pharmaceutical and chemical industry for managing and tracking batches or
production lots across the whole production process – even across multiple systems (SAP and non-SAP).
In various industry sectors, particularly the process industry, you have to work with homogeneous partial quantities of a
material or product throughout the entire quantity and value chain. In the SAP system, a batch is the quantity or partial
quantity of a particular material or product that is manufactured according to the same recipe.
There are various reasons for this:
- Legal requirements, for example, guidelines on good manufacturing practice (GMP), or regulations on hazardous materials.
- Defect tracing, recall activities, and recourse requirement.
- The requirement for differentiated quantity-based and value-based inventory management, for example, through heterogeneous
yield/result quantities or unequal constituents in production.
- Usability differences and the monitoring thereof in materials planning, sales and distribution, and production.
- Production or technical requirements, for example, material quantity calculations on the basis of different batch specifications.
WIP Tracking
WIP tracking provides increased visibility and traceability of work-in-process (WIP) through an ability to put WIP on stock,
send WIP to subcontractors, and describe individual items in WIP by characteristics
Detailed tracking of material flow through production order from component to finished product at the level of individual
item enables more precise recalls
Electronic Shift Report
The electronic Shift Report (Shift Book) replace all kinds of handwritten shift books. The shift report is a PDF document
that is generated at the end of a shift. This Shift Report provides an aggregated overview of all activities and events that
are relevant for the specific shift. It can be signed digitally to ensure correctness. The shift report thus facilitates shift
handover.
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Configuration VariantsManufacturing Execution (Discrete Manufacturing)
Manufacturing Execution (Process Manufacturing)
Manufacturing Execution (Repetitive Manufacturing)
Dispatching/ Scheduling
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| Shop Floor Integration |
Shop Floor
Integration with SAP MII
SAP MII enables
real-time transactional integration between plant floor and
enterprise (SAP ERP) systems out-of-the box through:
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Universal Connectivity
to the data, functionality and processes of existing plant floor
systems
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Business Logic for
creating automated events, KPIs and alerts
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Data Aggregation
and Transformation services
to synchronize plant and
Enterprise business processes
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Message mapping
between MES, SFA, legacy apps. and the ERP system based on industry
standards (like ANSI/ISA-S95, ...)
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Manufacturing
Intelligence: Near real-time analytics engine that aggregates and
delivers unified visualization of events, alerts, KPIs and decision
support to production personnel.
Shop Floor
Integration with SAP Enterprise Services
Various
Enterprise Services Bundles* help you to integrate your
manufacturing processes between your ERP system and 3
rd
party shop floor systems:
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Integration of Manufacturing
Execution Systems (MES)
This solution integrates heterogeneous shop floor systems,
enhances interoperability, reduces manual data input and
synchronizes manufacturing relevant master data and transactional
data between SAP ERP and Manufacturing Execution Systems.
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Manufacturing Work
Instructions
This solution integrates SAP ERP with shop floor systems, offering
a "Paper on Glass" approach to manufacturing.
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Batch Traceability and
Analytics
This ES bundle supports the tracking of batches or lots of
material through process, continuous or discrete production
environments. Batch tracking information is coordinated with plant
inventory, laboratory analyses, and inventory movement information
to provide powerful lot genealogy reports. It can also be combined
with appropriate data on equipment from real-time data
systems.
- Enterprise Services (ES)
bundles are collections of enterprise services that can be used to
extend the functionality of SAP ERP or other solutions of the SAP
Business Suite.
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| Supervision and Control |
Manufacturing visibility
manages events throughout the production process from release of a
manufacturing order through transferring the data to the data
warehouse, where it is analyzed. During production, process steps
but also exceptions are reported, ensuring a transparent
manufacturing process and the possibility to take counter-measures
immediately. It is also possible to provide information on events
to external parties such as customers, subcontractors or sold-to
parties, using various channels to provide the information quickly
and to ensure transparency of planned and actual events and to
continuously improve the manufacturing processes.
Shift supervisors and production managers
get additional functionality to monitor, track and record
shift-related events with shift notes and shift reports. This
information serves as a basis for handing over the shift and it can
also serve as an official record for regulatory or legal
purposes.
Regarding Quality Management, it is possible to enhance the
report by quality notifications and inspection lots that have been
created or changed during the selected shift.
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