SAP’s 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 & 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

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 . Product.Beverage Manufacturer Business Drivers Line Efficiency and Manufacturing Reporting/Automatic Production Confirmations Results Tight SAP ERP integration using MII Efficiency by Plant. Asset. Line. … 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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Real World Applications Beverage Manufacturer Global Electronics Manufacturer Defense Contractor – Missile Manufacturer Food Processor Metal Fabrication & Lawn Mower Manufacturer Building Products Manufacturer .

) Kronos MII Interface (Seeit Developed) Provide local survivability in cases where SAP is down globally Currently using MII for Shopfloor SAP interactions (confirmations. schedule.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) 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 . etc.

downtime. etc. and date .) 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.Molex – Shopfloor Information System Objectives Allow for SAP Production Order Confirmations utilizing actual machine data (quantities. 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. shift. operator. plan.) Enable the ability to gather machine events details for production and downtime occurrences linked by production order. etc. actual vs. production rates. tool. date. scrap. shift. production order numbers.

Plant Overview .

Department Overview .

Machine Overview .

Machine Downtime Details .

Post Production Confirmation to SAP .

Post Machine Downtime and Reasons to SAP .

Production Order Details .

Daily .Production Plan Overview .

Production Plan Overview .Weekly .

Shift Production Report .

Report – Top 10 Stopped Machines .

Report – Machine Top 10 Downtime Reasons .

Report – Downtime Events over 15 Minutes .

Main Menu .Handheld .

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 .

etc) CMM Interface SAP QM Interface . etc. qc data.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.) QM interface & CMM interface Provide local survivability in cases where SAP is down globally Currently using MII for Shopfloor SAP interactions (inspections. inspections.

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 .

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

Building Products Company Example .

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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 100’s 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 .

planned Automatic Updates to ERP for actual by product. actual vs.Metalcraft—Industrial Lawn Mowers/Parts Shop floor job tracking Operator User Interface for labor/job tracking Recording steps. multi-plant . crew. … 800+ Users.

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 .

Cost Center.Labor Efficiency Dashboard Multiple reporting selections Date ranges By WO. Shift. Work 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 .

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 .directional interface between Kronos Workforce Timekeeper & Activities to SAP PP/PP-PI.a shop-floor scheduling updated from SAP planned orders or APO • mi•Scoreboards™ .use mobile devices to transact to and from SAP ERP and receive real-time reports • mi•Touchscreen™ .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™ .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™ . & HR • mi•Mobile™ .an application that provides transactions to update your SAP HR and CATS • mi•SPC Shopfloor™ .interface data to SAP ERP from your Process Historian • mi•Production Scheduling Board™ .a shop-floor application designed by the user with direct updates and interaction with SAP ERP • mi•Labor Tracker™ .

Questions… .

bader@seeitmii.seeitmii. Program Manager www.seeitmii.com T C (262) 378-4699 (847) 612-8497 kevin.com SeeIT Solutions LLC Brian Kuchinski Sr.Contact Information SeeIT Solutions LLC Kevin Bader Partner www.com T C (847) 483-8703 (847) 456-7534 .

Data Collection from I/O to SAP ERP P o w erCo nn ect 100M LNK /ACT POW E R FDX 1 2 3 4 5 6 7 8 9 201 6 1 3 5 7 9 11 13 15 10 11 12 13 14 15 16 2 4 6 8 10 12 14 16 .

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