SAPs MII Real World Manufacturing Applications

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

Introductions: SeeIT Solutions SeeIT Solutions

100% focused on SAP Plant Floor to ERP solutions
From I/O & PLCs 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

Current Status

Excel and Paper Analysis

MII = Manufacturing Integration and Intelligence

EMO
ERP/MRP

Automated processes ERP visibility Composite metrics

SAP MII

Automated ERP transactions

Operational Excellence

TPM/Lean Manufacturing

Continuous Improvement

Six Sigma Service enablement

Manufacturing Integration

Manufacturing Intelligence

Real World Applications

Beverage Manufacturer Global Electronics Manufacturer Defense Contractor Missile Manufacturer Food Processor Metal Fabrication & Lawn Mower Manufacturer Building Products Manufacturer

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

Real World Applications

Beverage Manufacturer Global Electronics Manufacturer Defense Contractor Missile Manufacturer Food Processor Metal Fabrication & Lawn Mower Manufacturer Building Products Manufacturer

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

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

Plant Overview

Department Overview

Machine Overview

Machine Downtime Details

Post Production Confirmation to SAP

Post Machine Downtime and Reasons to SAP

Production Order Details

Production Plan Overview - Daily

Production Plan Overview - Weekly

Shift Production Report

Report Top 10 Stopped Machines

Report Machine Top 10 Downtime Reasons

Report Downtime Events over 15 Minutes

Handheld - Main Menu

Handheld Post Production Confirmation to SAP

Handheld Downtime Confirmation to SAP

Real World Applications

Beverage Manufacturer Global Electronics Manufacturer Defense Contractor Missile Manufacturer Food Processor Metal Fabrication & Lawn Mower Manufacturer Building Products Manufacturer

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

Inspection Results Acceptance and Posting to SAP

Production Order Entry

Characteristic Selection

SPC Display

Result Comment Entry

Characteristic Data Details

Real World Applications

Beverage Manufacturer Global Electronics Manufacturer Defense Contractor Missile Manufacturer Building Products Manufacturer Metal Fabrication & Lawn Mower Manufacturer Food Processor

Certainteed Building Products

Shop floor reporting/information system Quality focused projectLost production reporting Production reporting: Safety, VOC, Inventory, Production Targets and actual vs. targets recorded Historian Interface (Real-time and Historical data) Factory Event Interface 4000+ users over many plants

Building Products Company Example

Real World Applications

Beverage Manufacturer Global Electronics Manufacturer Defense Contractor Missile Manufacturer Building Products Manufacturer Food Processor Metal Fabrication & Lawn Mower Manufacturer

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 100s of assets per plant-many plants back to central ERP

Packaging Operator Examples

Packaging Performance Details

Packaging Machine Details

Packaging Quality Dashboard

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

Food Processor Lunchroom Scoreboard

Food Processor Management Dashboard

SPC Net Weight Dashboard

HVAC Boilers Chillers Air Comp. Electric Power

Gas This place gives

me a headache

Asset Management
Environmental

Maintenance Management

Energy Management

Lighting Control

Digital Dashboards

Real World Applications

Beverage Manufacturer Global Electronics Manufacturer Defense Contractor Missile Manufacturer Building Products Manufacturer Food Processor Metal Fabrication & Lawn Mower Manufacturer

MetalcraftIndustrial 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

Interfaces

SAP HR, PP, MM & IM modules 3rd Party Dynamic Nesting software Passing Work Order data Receipt of transactional data Automatic Goods Movement (Issue) of material 3rd Party Label Printing software Warranty Tracking database (internal)

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

Main Operator Menu

Operator Clock In

Secure scanning of employee badges for ALL transactions

Time Clock functionality

Job On/Off
Work order data scanned from shop packet

Reporting of good & scrap qtys Request to print a travel ticket

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

Supervisor Panel

Supervisor Screens

Discrepancies indicated by radio lights

Time & Attendance review and Absence entry

Labor Efficiency Dashboard

Multiple reporting selections Date ranges By WO, Shift, Work Center, Cost Center, Employee

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

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

Seeit Solutions MI Applications?

Partial listing of some of Manufacturing Intelligence (MI) application templates and interfaces that Seeit has developed:
miPerformance Metrics - configurable performance metrics enabled by a Performance Event Database miWorkforce - directional interface between Kronos Workforce Timekeeper & Activities to SAP PP/PP-PI, & HR miMobile - use mobile devices to transact to and from SAP ERP and receive real-time reports miTouchscreen - a shop-floor application designed by the user with direct updates and interaction with SAP ERP miLabor Tracker - an application that provides transactions to update your SAP HR and CATS miSPC Shopfloor - shop-floor SPC application presenting real-time Quality and Attribute data collection & charting with updates to SAP QM and PP/PP-PI miIntelligent Historian Connect - interface data to SAP ERP from your Process Historian miProduction Scheduling Board - a shop-floor scheduling updated from SAP planned orders or APO miScoreboards - 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

Questions

Contact Information

SeeIT Solutions LLC

Kevin Bader
Partner
www.seeitmii.com

T C

(262) 378-4699 (847) 612-8497

kevin.bader@seeitmii.com

SeeIT Solutions LLC

Brian Kuchinski
Sr. Program Manager
www.seeitmii.com

T C

(847) 483-8703 (847) 456-7534

Data Collection from I/O to SAP ERP

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