Professional Documents
Culture Documents
Business Considerations
• 2006 sales:
42.1 billion Swiss Francs
• Core businesses:
Pharmaceuticals and Diagnostics
X
Learning about machine, material, and quality issues
too late to take action
Visibility
Customer orders lost on the factory floor
Little visibility into actual production costs or KPIs
X
manufacturing exceptions
Ability to balance supply with demand priorities
Responsiveness Ability to exploit new profitable revenue
opportunities
X
shortages
Budget violations, inefficient processes and lost
Performance revenues
Lower customer satisfaction and employee
productivity and morale
Manufacturing Performance at Roche / Robert Fretz / 6
Pharmaceuticals
Company Background and Challenges
Business Considerations
Excellence in Operations
• Product • Samples
Plan
Plan • Timeframe • Pass/Fail Release
Release
• Quantity • CoA
• Plant
• Cycle Times
• Units
• Quality Analyze
Analyze
Prepare
Prepare • Recipes
• KPI Metrics
• Master Batch Record
• Training
• Batch Record
Report
Report
• Exceptions
• Operator Procedures
Instruct
Instruct • Checklists
Covered by
• Automatic Execution Shop-Floor-Systems • Values
Operate
Operate • Machine Parameters • Checks Record
Record
• Recipe Execution • Events
• Product • Samples
Plan
Plan • Timeframe • Pass/Fail Release
Release
• Quantity • CoA
• Plant
• Cycle Times
• Units
• Quality Analyze
Analyze
Prepare
Prepare • Recipes
• KPI Metrics
• Master Batch Record
• Training
• Batch Record
Report
Report
• Exceptions
• Operator Procedures
Instruct
Instruct • Checklists
Covered by
• Automatic Execution Shop-Floor-Systems • Values
Operate
Operate • Machine Parameters • Checks Record
Record
• Recipe Execution • Events
• Product • Samples
Plan
Plan • Timeframe • Pass/Fail Release
Release
• Quantity • CoA
• Plant
• Cycle Times
• Units
• Quality Analyze
Analyze
Prepare
Prepare • Recipes
• KPI Metrics
• Master Batch Record
• Training
• Batch Record
Report
Report
• Exceptions
• Operator Procedures
Instruct
Instruct • Checklists
Covered by
• Automatic Execution Shop-Floor-Systems • Values
Operate
Operate • Machine Parameters • Checks Record
Record
• Recipe Execution • Events
• Product • Samples
Plan
Plan • Timeframe • Pass/Fail Release
Release
• Quantity • CoA
• Plant
• Cycle Times
Prepare
Prepare
• Units
• Recipes SAP • Quality
• KPI Metrics
Analyze
Analyze
• Master Batch Record
• Training xMII
• Batch Record
Report
Report
• Exceptions
• Operator Procedures
Instruct
Instruct • Checklists
Covered by
• Automatic Execution Shop-Floor-Systems • Values
Operate
Operate • Machine Parameters • Checks Record
Record
• Recipe Execution • Events
• Product • Samples
Plan
Plan • Timeframe • Pass/Fail Release
Release
• Quantity • CoA
• Plant
• Cycle Times
Prepare
Prepare
• Units
• Recipes SAP • Quality
• KPI Metrics
Analyze
Analyze
• Master Batch Record
• Training xMII
• Batch Record
Report
Report
• Exceptions
• Operator Procedures
Instruct
Instruct • Checklists
Covered by
• Automatic Execution Shop-Floor-Systems • Values
Operate
Operate • Machine Parameters • Checks Record
Record
• Recipe Execution • Events
Manufacturing
Intelligence
Dashboards SAP BI
mySAP ERP
mySAP SCM
SAP xMII
Manufacturing
Intelligence
Dashboards SAP BI
mySAP ERP
mySAP SCM
SAP xMII
Manufacturing Integration: A single
ISA-95 compliant layer enabling SAP ERP
Manufacturing Integration connectivity into real-time plant floor apps. (MES,
SFA, legacy apps.) to drive plant-to-enterprise
business process interoperability
Manufacturing Performance at Roche / Robert Fretz / 15
Pharmaceuticals
What is the SAP xApp
Manufacturing Integration and Intelligence
(xMII)?
The SAP xApp Manufacturing Integration and
Intelligence (xMII) is a packaged composite
SAP NETWEAVER application that delivers:
Manufacturing Intelligence: Real-time
Other SAP Bus. Solutions
mySAP ERP
mySAP SCM
SAP xMII
Manufacturing Intelligence
Manufacturing Integration: A single
ISA-95 compliant layer enabling SAP ERP
Manufacturing Integration connectivity into real-time plant floor apps. (MES,
SFA, legacy apps.) to drive plant-to-enterprise
business process interoperability
Manufacturing Performance at Roche / Robert Fretz / 16
Pharmaceuticals
What is the SAP xApp
Manufacturing Integration and Intelligence
(xMII)?
The SAP xApp Manufacturing Integration and
Intelligence (xMII) is a packaged composite
SAP NETWEAVER application that delivers:
Manufacturing Intelligence: Real-time
Other SAP Bus. Solutions
SAP BI
Dashboards Start and stop times
• Create mfg plan
Quality and lab data
• Scheduling
Process history
• Release work order
Best practice deviations
• Close order
Efficiency
• Shipping and logistics mySAP ERP Downtime tracking
mySAP SCM Rework scrap rates
SAP xMII
Manufacturing Intelligence
Equipment Tracking and Performance Manufacturing Innovation Downtime and OEE Reporting
Manufacturing Integration
……
Office Network
SCADA
MES
… SPS
Shop IPC
Floor Lab
Manufacturing Performance at Roche / Robert Fretz / 19
Pharmaceuticals
Challenge:
Company-wide production communication
Room MES LIMS Office Performance Office Release
Monitoring Client Report Client Report
……
Office Network
Shop IPC
Floor Lab
Manufacturing Performance at Roche / Robert Fretz / 20
Pharmaceuticals
Challenge:
Company-wide production communication
Room MES LIMS Office Performance Office Release
Monitoring Client Report Client Report
……
Office Network
Shop IPC
Floor Lab
Manufacturing Performance at Roche / Robert Fretz / 21
Pharmaceuticals
Real-Time Integration Platform Selection Process
– Product Categories and Alternatives
– Selected product:
Business Considerations
Use Case:
SAP xMII Dashboard
Real-time acquisition of batch KPI
directly at the end of batch and
presentation of measured and calculated
values (quality, duration of phases)
SAP xMII (SPC Engine,
Real-time KPI Calculation)
Goals:
Better process understanding (SPC)
Faster pro-active deviation management
Demonstrates the integration of shop Historian
floor data
Demonstrates reaction to events in the
process
SCADA
Pharmaceuticals
Download Order-Dependent Setpoints
2 3
Goals:
Increase speed of bringing data together SAP xMII with Dashboard
Avoid failures from manual data entry
Demonstrates transfer of SAP ERP orders
4
Demonstrates download to shop floor
Use Case:
SAP ERP
Automatic update of all material
consumptions in SAP directly after finishing
batch
SAP xMII: Real-time
Goals: Calculation
Business Considerations