SAP Perfect Plant

Manufacturing Solution

Linking Top Floor & Shop Floor with Actionable Intelligence Public

Matt Chan
SAP Manufacturing Solution Principal APJ
 Agenda

 SAP Manufacturing Solution Introduction

 System Overview
 Case Studies
 Valero – Oil & Gas
 Tiger Forest Paper – Paper
 Usiminas - Steel

© SAP AG 2010. All rights reserved. / Page 2 Public

 SAP for Manufacturing: End-to-end Solution
Produktion – Funktionales Schichtenmodell (gemäß ANSI/ISA-95.00.01-2000, Teil1)

Level 4 Business Planning & Logistics

Enterprise Business Processes Plant/Cross-Plant Production Scheduling, Shipping,
Receiving, Inventory, etc
SAP ERP,
SAP SCM,
...

Level 3
Manufacturing Operations
Dispatching Production, Detailed Production Scheduling,
SAP
Manufacturing Operations
(Shop Floor Level) Order Execution, Tracking &Traceability,
Prod. Data Collaboration, Prod. QM
Manufacturing
 Execution
 Integration
Level 2
Automation / Device Integration Data Historians  Intelligence
Connectivity

Level 1 Plant Data Collection Sub-Systems

Shop Floor
RFID Weigh Inspection Environmental PLC/DCS
Process Control Sensors Scales Equip/Testers Bldg Mgmt Sys SCADA

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 What Operational Challenges Manufacturers
Face

Plant Manager/Supervisor:
exception report is Time-
intensive, Error-prone
CXO: Poor Visibility into Impact: Lack of in-time decision support (1 day)
Operations
Impact: Difficult to benchmark (1 Week)

Indonesia
Malaysia
HQ

India

China
Japan
Thailand
Engineers: Silo view, cross
function data is inaccessible
Impact: For example, difficult to know how one
lot ran versus another and how that may
correlate to quality (Paper work)

© SAP AG 2010. All rights reserved. / Page 4 Public

 SAP Perfect Plan Solution

SAP Business Solutions

Enterprise
Layer
(SCM, PP, PP-PI,MM,QM…)

SAP MII SAP ME

Integration & Intelligence Manufacturing Execution
Factory
Layer

Machine & Control System

Shopfloor
Equipment LIMS Historian HMI Weigh Scale PLC SCADA Inspection EQP

© SAP AG 2010. All rights reserved. / Page 5 Public

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 Solution Reduces Losses at the Plant, Shares
Best Practices and Increases Visibility

 Deployed at 17 Refineries, integrating:

 4 distinct process historians
 Dozens of other unique legacy systems
and databases
 Proprietary technologies
 Highly detailed and inconsistent data
 Distributed environment w/sensitive
bandwidth
 Created visually stimulating UI
 Executive Operations Center
 Media wall
 Plasma panorama
 Graphical, colorful, meaningful display
 Process Control Metrics
 Volume analysis
 Inventory control
 Process safety statistics
 Energy stewardship

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 Corporate Operations Dashboard

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 Energy Stewardship Dashboard – Plant Level

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 Energy Stewardship Dashboard – Unit Level

© SAP AG 2010. All rights reserved. / Page 11 Public

 Tiger Forest Paper Synchronize Enterprise and Shop Floor
with SAP MII
QUICK FACTS
 Tiger Forest Paper
 Industry: Mill Products – Pulp and Paper
 Revenue: US$1.4 billion
 Headquarter: Changsha, China
 Website: http://www.tigerfp.com
 SAP Solution: SAP Manufacturing
Integration and Intelligence
Why SAP MII
 Ease of integration with core SAP
software and manufacturing execution
Systems
 Agility to build graphs and dashboards
 Capacity to integrate with control system
© SAP AG 2010. All rights reserved. / Page 12
Key Challenge
Isolated shop floor management applications through 6
manufacturing bases
Standardize processes across plants to scale up best
practices
Provide visibility into disparate data sources, easy information
access, and analytics to support processes
Protect and leverage existed IT investment
Implement Practice and Operational Benefit
Implement at 1 plant initially and then roll-out to other plants
Completed 1st plant implementation in 3 months, on
schedule and within budget
Improved and streamlined connectivity
with 1 application to integrate many data
sources
Avoided costly development and maintenance of interfaces
Public
 Tiger Forest Paper Phase I Went Live on July 15th 2010
Out-of-Box integration between ERP and in-house MES in Yueyang Plant

No. Interface Data Object Sender /Receiver Technique Sender System Receiver System Message Type Msg count (per
hour)
101 Material Master Data aRFC SAP ECC MES RFC

SQL
102 Inspection Lot aRFC SAP ECC MES RFC

Web Service
103 Production Order aRFC SAP ECC MES RFC

Web Service
104 Production Order Status Web Service MES SAP ECC RFC

aRFC
105 Outbound Delivery aRFC SAP ECC MES RFC 50-80 outbound
 delivery per day
Web Service
106 Goods Movement Web Service MES SAP ECC RFC 10,000 GR per day

aRFC
107 Reply message aRFC SAP ECC MES RFC

Web Service
108 Good Issue Data Web Service MES SAP ECC RFC

aRFC
109 Batch characteristics Web Service MES SAP ECC RFC

aRFC
110 Stock Transfer Order aRFC SAP ECC MES RFC

Web Service
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 USIMINAS implemented SAP MII

USIMINAS Video Wall

http://www.youtube.com/watch?v=xmRYPE1A
_Oo&feature=player_embedded

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 SAP Manufacturing Execution Customers
Experience & Global Manufacturing Plants

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 SAP MII is the choice of 500+ Customers and
1500+ plants varying various industries

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We Welcome Your Questions

Thank you!
Matt Chan Public

SAP Perfect Plant Solution Principal

matt.chan@sap.com
Tel: +86 (21) 3302 4898 #3558
Cell: +86 13828811331