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Is your ERP system
ready for the digital era?
Investing in Germany | A guide for Chinese businesses
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Industry 4.0 |
Is your ERP system ready for the digital era?
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Investing in Germany | A guide for Chinese businesses
Industry 4.0 |
Is your ERP system ready for the digital era?
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Investing in Germany | A guide for Chinese businesses
Our
understanding
of Industry 4.0
Owing to the growing uncertainty in the market
and the customer’s desire for more individualized
products, companies are coming under pressure
to make their production and logistics processes
more flexible. The key word is Industry 4.0. The en-
tire IT infrastructure must therefore be redesigned –
this includes systems for the planning, control, and
execution of production and logistics. The key to
process integration is innovative data management
with an Enterprise Resource Planning (ERP) system
as central planning instance. First, the term Indus-
try 4.0 and its relation to a company’s EaRP system
will be defined.
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Industry 4.0 |
Is your ERP system ready for the digital era?
business functions of a •• Shorter lead times through the application of intelligent analyses
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Industry 4.0 |
Is your ERP system ready for the digital era?
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Investing in Germany | A guide for Chinese businesses
Demands on
ERP Systems made
by Industry 4.0
If the ERP system is to be used in a CPS environment
to support Industry 4.0, it must fulfill a variety of
technical and process-related requirements which
are described below.
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Industry 4.0 |
Is your ERP system ready for the digital era?
Technical requirements
Data becomes more and more the key to maximizes the value of data for the busi-
the planning, control, and execution of all ness and includes the storage, exchange,
activities along the supply chain. That is and use of data. The development and
why companies must handle all data with implementation of such concepts must be
care and make wise use of them. Compa- encouraged, as only data which is error-
nies must look for new ways of using data free, up-to-date, accessible, and usable
and need to exploit the opportunities of can contribute to the company’s success.
their data security to create an effective In conclusion, technical challenges lead
basis for decision-making. The main chal- to technical requirements (TR1, TR2, and
lenge here is innovative data management. TR3) for ERP systems which are shown and
For us, innovative data management is a described in Figure 2.
comprehensive, long-term concept which
TR3 Visualization:
Data use •• The user interface of the ERP systems should display information adequately (i.a. display on different devices),
understandingly und intuitively
•• Goal: improvement of human-machine interaction
Automation:
•• ERP system should use the data to trigger automated processes
•• Goal: reduction of errors and increase in efficiency
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Investing in Germany | A guide for Chinese businesses
TR1 – Data storage: logically simplified On the other hand it is possible to store
and physically distributed data decentrally where there is no hierar-
There are two perspectives on data stor- chy of IT systems. In such a scenario, the
age, the logical and the physical. The logical independent systems start communicating
perspective describes the data model with each other when there is the need to
and hence the structure of the database solve temporary tasks such as finding the
which serves as the central instance for the next work station for the processing of the
company‘s data management. Typically, an work piece. This theoretically achieves the
ERP system is based on a number of tables desired flexibility. Nevertheless, there is no
which store fundamental data as single en- way to avoid redundancies and inconsisten-
tries, aggregated intermediate results, and cies in that case. General data such as, e.g.,
condensed data. For classic ERP systems the organizational structure and material
these condensed data are based on com- master data have to be managed centrally.
putation routines which can be executed Moreover, it is also important for flexible
at predefined time intervals only. This is production to plan sequences in advance
due to a lack of performance which leads in order to have sufficient resources (per-
to data not being up-to-date. An example sonnel, budget, etc.) available. This is why
would be the posting of inventory between it is a challenge in Industry 4.0 to balance
storage locations. The flexibility which is centralized and decentralized data storage
necessary for Industry 4.0 is only achieva- to avoid redundancies and inconsistencies,
ble if the planner is able to access the most allow for planning, and realize the desired
current data from all business functions. flexibility. This is summarized in Figure 3.
This requires the development and im-
plementation of a simplified data model
which allows access to a current, single set
of data at all times and which also updates Fig. 3 – Data storage
upstream results.
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Industry 4.0 |
Is your ERP system ready for the digital era?
Horizontal Integration
ER
ion
P
at
gr
Supplier Customer
te
l In
ca
M
rti
ES
Ve
PL
C
Manufacturer
Vertical Integration: Exchange of data between the ERP system, the MES, and the shop floor
Horizontal Integration: Exchange of data along the supply chain through the integration of customers and suppliers
TR2 – Data exchange: integrated and A vertical integration of the planning, con- The flexible planning,
immediate trol, and execution levels in the company
As companies interact with other parties additionally enables flexible control of control, and execution of
such as suppliers, institutions, and cus- production and logistics processes. For production requires vertical
tomers beyond their boundaries, an ERP example, production orders are exchanged
system has to be able to support end-to- between the planning level, ERP system, and horizontal connection
end processes and to exchange data with and the execution level, manufacturing of data generated by
these external parties. This horizontal inte- execution system (MES). The latter then ex-
gration facilitates the consistent availability changes data with the machine’s program- different systems.
of customer and supplier data. Horizontal mable logic control (PLC). The challenge
integration is one of the strengths of ERP that arises is hence the connection of the
systems, thanks to their existing interfaces. ERP system in two directions – horizontal
and vertical (see Figure 4).
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Investing in Germany | A guide for Chinese businesses
For horizontal integration beyond the TR3 – Data use: intuitively displayed, Apart from using data to trigger automated
company‘s boundaries it is vital to define integrated and automated execution or at least other processes, the
and establish communication standards To maximize the potential of company data visualization of data is important for involv-
for data security and to avoid data manip- it is important not only to store and ex- ing the user. The user therefore needs to
ulation. As the IT systems of the different change data but also to use them effective- have the possibility to interact with the ERP
supply chain partners communicate using ly and efficiently. Such advanced data use system, using an adequate user interface.
a number of interfaces it has to be ensured has to be applied to all data, independently The design and configuration of such user
that the technologies are capable of being of their storage location – but especially to interfaces which are based on self-explan-
integrated. the data which are physically distributed. atory elements for the visualization and
For us, advanced data use also considers the mobile use of data on different devices
Apart from the possibility of connecting dif- user-friendly human-machine interaction, such as smartphones and tablets provides
ferent systems with each other, the speed data connection among different com- an enormous potential from a process-re-
of the data access of ERP systems and panies, and the automation of business lated point of view. The easier it is for the
connected data sources is another chal- processes. The challenge is the realization. user to work with ERP systems, the more
lenge that presents itself. As mentioned Over recent decades, companies have efficient and more transparent process
earlier when discussing logically simplified collected large amounts of data but they execution will be and the fewer errors will
data storage, the planner has to be able to are still at an early stage of using it wisely. be made during data input. To exploit the
access the most up-to-date data to super- The reason for this is that the existing data full potential of such interfaces they should
vise and, if necessary, influence production have to be connected intelligently to new in- have the following five characteristics:
and logistics processes. This is why ERP formation. Only if large amounts of data are
systems need to have minimal response connected can Big Data become Smart Data.
times. If data is stored in different places,
data exchange is essential for process exe- An example is the collection of data from
cution and immediate data access is even the various machine tools with the help of
more important. It is thus obvious that a sensors. These collected data are then en-
concept for innovative data management riched with technical data such as thresh-
must integrate the storage, exchange and – old values and historical data, commercial
to be explained next – use of data. data such as costs, and external data such
as demand forecasts, to create new busi-
ness-relevant information. The resulting
key performance indicators (KPIs) serve as
a basis for analyses and reports. Automa-
tion, either partial or complete, can take
place on the basis of these processes. For
example, imagine the automated procure-
ment of material based on the expected
demand in the next planning period and
the current inventory level. When projected
stock falls below a threshold, purchase req-
uisitions are automatically generated and
purchase orders are sent out to the supplier.
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Industry 4.0 |
Is your ERP system ready for the digital era?
Role-based –
the user interface provides the
functionalities of ERP systems to
Mobile – the user as needed for the job role
the user is able to access informa- and tasks. Information is displayed
tion about production processes and analyzed accordingly.
at any time and anywhere and
may change control parameters
promptly.
Personalized –
the user interface provides the
user with modern functionali-
New role of ties which give the impression
ERP systems that the work is supported
according to individual needs.
This way a bond between the
user and the working medium
is established.
Simple –
complex functionalities of the
ERP systems are divided into sin-
gle steps which the user executes
one after another. The simplifica-
tion of the user interface increas- Agile –
es the efficiency and reduces the the user interface enables
probability of errors. the user to work quickly and
without delays with an ERP
system. Information is called,
processed, and visualized
immediately.
New role of ERP systems in data stor- on real-time data which can be accessed dancies and inconsistencies while dynamic
age, data exchange, and data use on various devices with a modern user data such as transactional data for orders
In Industry 4.0, ERP systems will fulfill a new interface replacing access to tables with the could be stored decentrally to allow for
role. Typically, an ERP system is the central help of transactions. flexibility. Data exchange with all IT systems
instance for data storage in a company to has to be planned carefully and there is a
plan, control, and execute business pro- All dimensions of innovative data manage- need to assess which novel technologies
cesses. This is the ERP system’s strength ment – data storage, data exchange, and such as sensors, analytic algorithms, and
which continues to exist. But the ERP sys- data use – are affected by the new role of data glasses are able to make the use of
tem has to be embedded into an upstream, ERP systems. An adequate concept has to ERP systems even more efficient.
connected system consisting of intelligent be developed individually for each compa-
components. It will still be the central part ny to maximize the benefits of Industry 4.0.
of this entire system but for example not all For example, it has to be decided which
data will be stored in the ERP system’s da- data should be stored centrally in the ERP
tabase any longer. Moreover, the connec- system and which data it is advisable to
tions to other IT systems become more and store decentrally on the workpiece itself.
more important and so does data use. The Static data such as material master data
planner receives intelligent analyses based could be stored centrally to avoid redun-
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Investing in Germany | A guide for Chinese businesses
Process-related
requirements
To achieve the goals of Industry 4.0 listed
in Figure 1 (higher flexibility, increasing Lean Management and
quality, etc.) processes along the supply
chain have to be adjusted. In particular, the Industry 4.0: lean and still flexible
increased flexibility in production is of great
importance to enabling the manufacture The focus in both concepts for all planning and controlling
of individualized products at low cost and activities is the customer and their need for individualized
with high resource efficiency. The idea products. This is why production models which are based on
of a flexible and adaptable production is requirements are used. The reduction of inventory which is a
not a new one. Nevertheless, Industry 4.0 form of waste in lean management is also aimed for in
changes the way of achieving the desired Industry 4.0. It should facilitate the steadily growing range of
flexibility compared to frequently used variants at low cost. A lot size of one is also requested in
management methods. Industry 4.0.
In Industry 4.0 ERP, systems will still play The main differences between Industry 4.0 and Lean Manage-
a central role but it has to be evaluated ment are the following: the static sequencing and release of
how they should be used to maximize their production orders and the worker, in additionto the machine,
potential for Industry 4.0. It is obvious that as central instance for production execution, e.g. for quality
new requirements for ERP systems exist. assurance. In Industry 4.0, production orders may be adjusted
Apart from the technical requirements frequently and are released just before executing the task that
described in the previous section, there was changed. This way the rough-cut and detailed production
are also process-related challenges to planning becomes less important as customer orders and re-
cope with. These challenges lead to new quirements can be committed directly to the production line.
process-related requirements (PR1 to PR6)
which are listed and described in Figure 5. Moreover, the approach to avoiding errors differs in Industry
4.0 from the one in Lean Management. In Lean Management,
quality is created throughout the process. It is the worker‘s
duty to identify errors and correct them cumulatively. This
leads to a continuous improvement for the company. But the
process is a reactive one and this is why Industry 4.0 uses
technologies proactively to identify errors. With the help of
continuous data collection, data consolidation and the use of
analytics, errors are detected before they interrupt producti-
on (predictive maintenance).
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Industry 4.0 |
Is your ERP system ready for the digital era?
Suitability for dynamic planning, •• Vertical integration to make the production planning and execution more dynamic
control, and execution
•• Bi-directional exchange and usage of decentralized stored data
Support for an integrated end- •• Horizontal integration e.g. with suppliers and customers
to-end process
•• Goal: integrated information and process flow along the supply chain
Location-independent control and •• Horizontal integration e.g. with suppliers and customers
execution of processes
•• Goal: integrated information and process flow along the supply chain
Process improvement through •• Use of all existing data from different data sources
intelligent data analyses
•• Generation of intelligent reports
•• Goal: decision support for predictive planning and control of processes and/or the trigger
of automated, subsequent processes
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Investing in Germany | A guide for Chinese businesses
PR1 – Suitability for dynamic planning, collaboration platform based on cloud This way the production manager can
control and execution: vertically inte- technology where metadata is stored. This supervise the manufacturing from afar, since
grated and interconnected way manufacturers profit from customer operating figures are displayed on a mobile
PR1 consists of two main criteria: the possi- feedback and can improve their machines. device. If there is any abnormality or the
bility of technically connecting ERP systems Operators can take over the asset master need for adjustments the manager can also
to MES and PLC and its support of decentral- data and spare parts information provided. intervene using a mobile device.
ized planning, control, and execution. Moreover, they can reduce their mainte-
nance costs and times, among other things Another example is the support of mainte-
The connection of the ERP system to the by shortening issue response times with the nance workers. Intuitive applications can be
MES and PLC creates a vertical integration of service providers. configured for their tasks so that the worker
different organizational levels. This facilitates receives e.g. part and maintenance informa-
a dynamic release of production orders that Horizontal integration is vital for implement- tion on a mobile device.
aims at manufacturing a large range of vari- ing Industry 4.0 as it permits the exchange of
ants at low cost. Changes to the production data easily and efficiently between different PR5 – Efficiency of process steps
order can be transmitted to the MES imme- business functions and supply chain part- supported by the system: fast and
diately through the integrated data exchange ners. adaptive
between the ERP system and MES. The MES The performance of processes that are sup-
sends the changes to the PLC of the machine PR3 – Progressiveness of the human- ported by the system contributes significant-
which adjusts the execution of the produc- machine interaction: efficient and ly to the flexibility of production. Faster data
tion order at once. error-free processing based on current data helps to
Process execution can become more effi- achieve the goal of a fast reaction to chang-
The decentralized planning, control, and cient and less error-prone if it provides a ing requirements.
execution of production is supported by the modern user experience. A user-friendly,
ERP system when it is able to exchange data personalized, and intuitive human-machine If there is any change in data it is important
that is stored in different places bi-direction- interaction and role-based and graphic (in- that all systems which have access to these
ally. This aims at making production even stead of transaction-based) data input and data are always synchronized. Only in this
more flexible (see paragraph on data storage output supports the worker’s daily activities. way can it be ensured that all business func-
in section 2.1). tions work with current and consistent data.
An example would be the collection, pro- If this is not the case, the repetition of work
PR2 – Support for an integrated end- cessing, and visualization of stock data with is an inevitable consequence. For example,
to-end process: horizontally integrated the help of modern devices. Stock informa- a change in the bill of materials in the ERP
and flexibly adjustable tion does not have to be written down on a system which is caused by poor quality
The technical connection of all business piece of paper and entered into a stationary influences not only the procurement process
functions and all external supply chain system any longer. It is now possible to enter where new parts have to be purchased but
partners creates horizontal integration and send the data to the ERP system on-the- also the production process as different
that aims at an integrated information and fly using an app. This reduces manual work components have to be used for the assem-
process flow along the supply chain. This way and minimizes errors during data collection. bly. Consequently, the new bill of materials
a supplier can react more swiftly when facing Additionally, the data in the ERP system has to be transferred to the MES which does
changes in the customer order or supply reflect the current stock situation at all times. the detailed planning for production steps
bottlenecks. Process parameters can be and resources.
adjusted flexibly according to changing re- PR4 – Location-independent control
quirements, while taking cost efficiency and and execution of processes: whenever
quality goals (on-time delivery performance) and wherever
into account. The ERP system should provide innovative,
mobile applications for user interaction,
An example that illustrates the benefits of for example via smartphones and tablets,
the horizontal integration of different supply ideally out-of-the-box. These applications
chain partners is the SAP Asset Intelligence should be applicable to all business-relevant
Network. It is a secure network which auto- processes and aim at flexible control and the
mates asset data exchange between OEMs, execution of processes from anywhere at
operators, and service providers using a any time.
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Industry 4.0 |
Is your ERP system ready for the digital era?
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Investing in Germany | A guide for Chinese businesses
Assessment
of existing SAP
technologies
SAP SE supports the trend towards Industry 4.0 with
technical innovations which can be differentiated be-
tween technologies for data storage, data exchange
and data use (see Figure 6). In the area of data storage
SAP SE offers the in-memory database system SAP
HANA, which speeds up data access. The integration
software SAP Plant Connectivity (PCo) in combination
with SAP ME and SAP MII can be used to exchange
data from the underlying ERP system down to the
machine control level. An example for an innovation
with regards to data use are SAP Fiori and UI5 Apps
with built-in analytical functions.
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Industry 4.0 |
Is your ERP system ready for the digital era?
SAP HANA DB Architecture SAP ME, SAP MII and SAP PCo SAP Fiori & UI5 Applications
The HANA database supports al- SAP ME, SAP MII and SAP PCo facili- SAP Fiori and SAP UI5 offer role-
most instant data access by storing tate data exchange between the ERP based applications and interfaces
data in fast memory, column-orient- level and the machine control level. on mobile devices. With the help of
ed data management, and the shift As a result, the program can incor- alerts, the attention of the user is
of program code from the applica- porate dynamic information. directed to critical situations, while
tion level to the database level. suggesting possible solutions.
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Investing in Germany | A guide for Chinese businesses
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Industry 4.0 |
Is your ERP system ready for the digital era?
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Investing in Germany | A guide for Chinese businesses
Status quo: a matter of time The interconnectivity of an ERP system with Having mentioned the technical benefits,
ERP systems which run software applica- boundary applications which is perceived however, on the software side the new da-
tions such as SAP ERP ECC on classic DB2 as a necessary requirement for a digital- tabase architecture does not even differen-
databases currently constitute the status ized company from a holistic point of view tiate which business processes have to be
quo for the majority of companies. For sev- is often only achievable at high cost and executed. The classic core ERP functionali-
eral generations these systems were im- with high configuration and development ties and the extended functionalities of the
plemented as a central planning element in effort. A digital reflection of the operational SAP Business Suite on HANA (see previous
most companies. Business processes in the processes and of the product itself, which section) are equally enabled to make use of
area of logistics, production, and finance can foster the adaptability of the entire the advantages.
were designed interactively sector- and production as a consequence of the in-
industry-wide around different modules creasing volatility, is difficult to realize with Using SAP HANA requires a technical
(procurement: SAP MM, logistics: SAP WM, those technical installations. In the medium migration of the existing data set from a
plant maintenance: SAP PM, production: and long term, these ERP systems will face traditional database to the new database
SAP PP, finance: SAP FI, controlling: SAP significant challenges to meet Industry 4.0 technology. This system conversion is an
CO). The end-user is able to access these requirements. initial but essential step towards a com-
functions by means of different transaction plete conversion to SAP S/4HANA which
codes which are mostly not connected to Evolution: on the way to digitalization can then be implemented later on. Through
a special business role. In order to extend Evolutionary ERP systems facilitate signif- the use of in-memory technology, Industry
the business processes beyond a compa- icant performance improvements in the 4.0 requirements can be met to a certain
ny’s borders SAP SE launched the SAP Busi- execution of business processes which extent by reducing the reaction time and
ness Suite which covers next to the core have not been possible with the classic hence increasing adaptability.
ERP modules functionalities for Customer systems so far. The SAP HANA database
Relationship Management (CRM), Supplier architecture combines different innovative
Relationship Management (SRM), Product software-related and hardware-related
Lifecycle Management (PLM) and Supply technologies. A hardware innovation is the
Chain Management (SCM). hybrid of the very common column-orient-
ed access functionality of an in-memory
The programs enabling the proper func- database and the classic row-oriented
tionality of these ERP systems such as technology that is popular for relational
postings and reports are based on data databases. An essential characteristic of
which are mostly selected from aggregated SAP HANA is its consequential in-memory
tables or index tables that in turn derive platform design which basically promotes
data from a larger variety of basic tables. the analysis and processing of data directly
This leads to an increased complexity of in random access memory instead of using
the system landscape which in particular the traditional hard-drive-based mode
causes negative effects on the availability of operation. This enables the execution
of data (e.g. blocking of objects through of transactional (Online Transaction Pro-
users) and access to data (e.g. no parallel cessing, OLTP) and analytical procedures
postings) and on the overall performance (Online Analytical Processing, OLAP) in the
of the entire system. Long access times, same system aiming at processing Big Data
long latency periods, and an inevitably high practically in real-time. The partial relo-
degree of data redundancy are the conse- cation of programs from the application
quences of the technical characteristics of layer directly into the database layer also
these systems. increases the performance of the system
which is seen as inevitable on the way
towards digitalization.
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Industry 4.0 |
Is your ERP system ready for the digital era?
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Investing in Germany | A guide for Chinese businesses
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Industry 4.0 |
Is your ERP system ready for the digital era?
Sales Order
VBAK VBAP VAKPA VAPMA VBAK VBAP
Delivery
LIKP LIPS VLKPA LKPMA LIKP KIPS
Billing Document
VBRK VBRP VRKPA VRMPA VBRK VBRP
Status Info
VBUK VBUP
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Investing in Germany | A guide for Chinese businesses
In the area of human-machine interaction, These technical innovations on the one information in the form of alerts when
SAP SE promotes its SAP Fiori UX strategy hand define a completely new working critical situations such as material shortag-
in which the transactional operating model experience and on the other permit the re- es are about to happen. In a next step the
is transformed into a role-based user ex- structuring of production landscapes from staff will be actively provided with deci-
perience. SAP Fiori is expected to steadily scratch. The related organizational changes sion-supporting recommendations based
replace the “old-fashioned” SAP GUI (Global will be even further-reaching than simple on algorithms that have been programmed
User Interface) with the aim of facilitating migration to a new database would be. The beforehand. In turn, the recommendations
transition into a new era in the field of new human-machine interfaces require can be simulated to evaluate the effects of
client-centric user experience. Modern in-depth training of staff in the use of these execution and finally can be used to make
user interfaces which are currently popular systems, since existing knowledge can only the best possible decision.
in the consumer industry (e.g. smartphone be transferred to a limited extent.
applications) enable this transmission by
replacing existing transactions with several In addition, SAP SE will increase the intel-
smaller individual SAP Fiori applications ligence of future generations of ERP sys-
designed for a specific business role as tems. Embedded analytics functionalities
shown in Figure 9. will be implemented in the core of SAP
S/4HANA Enterprise Management. These
context-based analysis and reporting func-
tionalities basically consist of virtual data
models which by nature are designed for
use by role-based SAP Fiori applications.
Thus, for example, a material or production
planner can be provided with particular
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Industry 4.0 |
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Connection of ERP
systems to the shop floor
Conventionally, production is planned In individualized production scenarios, SAP Plant Connectivity (PCo) enables the
top-down from the production planning consistent data exchange between product exchange of data between the MES level,
level (ERP system) to the execution level engineering and manufacturing execution supervisory control, and data acquisition
(MES) down to the machine control level plays an essential role as the interconnec- (SCADA) services, human machine inter-
(PLC). SAP SE responds to this requirement tion of these functions forms the start of faces (HMI) or programmable logic controls
by connecting the ERP system with the solid manufacturing processes. Conven- (PLC). SAP ME offers full integration with
MES and hence enabling the exchange of tionally, the Engineering Bill of Materials SAP ERP systems out-of-the-box. Non-con-
information between the top floor and the (EBOM) is handed over to the manufactur- formity management is supported by
shop floor in real time. That is what is called ing department, where mostly the system in-line sampling and system-guided manual
‘connected manufacturing’. (background job) based on the require- rework processes.
ments from engineering develops the Man-
All ERP system classes presented in the ufacturing Bill of Materials (MBOM). These
previous section can be used to vertical- routings are then a fixed pattern. With the
ly integrate with the production control aim of being more flexible, SAP launched
and execution levels and to dissolve the the SAP Visual Enterprise Manufacturing
automation pyramid. The ERP system’s Planner (VEMP), which permits the manu-
reach needs to be expanded towards the facturing engineer to create these MBOMs
machine layer. The machine layer itself has by re-grouping the parts and components
to be programmed more openly so that and be able to add other parts that are
the middle control layer which integrates needed for assembly/packaging processes.
the various data sources can manage the With regard to the imperative of a lot size
production process more autonomously. of one, the SAP VEMP is a beneficial imple-
mentation.
There are many reasons for performing the
orchestration of production execution in a SAP Manufacturing Integration and Intelli-
separate MES such as SAP Manufacturing gence (SAP MII) and SAP ME use the data
Execution (SAP ME) or equivalent. If there from the EBOM or rather the routing from
is a downtime in the ERP system’s connec- the MBOM. Both systems complement
tivity for whatever reason, production has each other. On the one hand, SAP MII
to keep running. Manufacturing processes integrates shop floor solutions such as SAP
usually need more detailed execution ME and other data sources with the ERP
operations than planned in the routing by system for production, quality manage-
ERP systems. It is not desirable to track ment, plant maintenance, and materials
every state of work in progress (WIP) for management. On the other hand, it is used
every production step. Regulatory compli- to visualize KPIs calculated by analyses of
ance and the imperative of a lot size of one the data extracted from the integrated
require a traceability and a product gene- data sources. SAP MII offers an alert frame-
alogy at the unit level. For that purpose work monitoring the threshold values for
parametric data need to be connected to any machine and creates preventive main-
the units. tenance work orders for each threshold
breach.
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Investing in Germany | A guide for Chinese businesses
ERP
· Production plan · Serial number management
· Bill of materials · Quality inspection results
· Variant management · Order confirmation
· Production steps · Inventory and equipments
ME/MII
· Production details · Log parametric data
management · Tolerance checks
· Production step routing · Return conformance or
· Shop floor controls non-conformance decisions
PCo
· Mapping of production details from the manufacturing
execution system to PLC control parameters
PLC
· Sensor detects part carrier · Machine reports completion
· Requests control parameters · Requests next operation
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Industry 4.0 |
Is your ERP system ready for the digital era?
SAP ME/MII and SAP Plant The material will be processed at the
workstation according to this information.
Connectivity enable vertical As soon as the production step is executed
data exchange between the results will be sent back to the ME. The
ME now executes the check and decides
the planning, control, and whether the production step can be set to
execution levels. complete or not. If the conformity check
is successful, the next work step for the
material will be identified dynamically. The
material will be sent to the next work sta-
It facilitates vertical integration from the tion where the PLC asks for control param-
ERP system to the machine level such that eters and the MES sends these using PCo.
the control program for machines does When all production steps are successfully
not have to be determined in advance any executed, the order conformation is sent to
more as usual. PCo is based on stand- the ERP. This process of exchanging data is
ardized communication interfaces which shown in Figure 10.
enable fast and easy configuration. It can
be dynamically fed with freely defined With the help of vertical integration and
parameters from superior levels which dynamic data exchange by means of PCo,
permits a fast adaption of the production different products can be manufactured
process to the customer’s needs as desired without a rigidly defined production se-
in Industry 4.0. PCo enables communica- quence, i.e. the production is now flexible.
tion between a source and a target system Moreover, production benefits from the
using OPC Unified Architecture (OPC-UA) advantages of mass production while man-
and other common protocols for machine ufacturing individualized products.
communication. Target and source systems
can be SAP ME, SAP MII, SAP ERM, SAP ERP,
SAP S/4HANA, SCADA, PLC, plant histori-
ans, 3rd party MES and sensors.
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Investing in Germany | A guide for Chinese businesses
Conclusion:
an initial but very
essential step
Fig. 11 – Assessment regarding technical requirements
TR1
Data storage
TR2
Data exchange
TR3
Data use
Does not meet requirements Meets requirements to a small extent Meets requirements partially
Meets requirements to a large extent Fully meets requirements
No matter whether the technologies Assessment with regard to technical leads to the possibility of using current,
presented in the area of ERP can be cate- requirements non-aggregated data. This leads to an im-
gorized as evolutionary or revolutionary, it Figure 11 shows the result of the system’s provement in the area of data storage.
makes sense to assess them according to assessment regarding the technical re-
the technical and process-related require- quirements data storage (TR1), data ex- Evolutionary and revolutionary ERP sys-
ments described in section 2. Apart from change (TR2), and data use (TR3). tems have an advantage in the area of data
the system’s technical degree of innova- exchange (TR2) compared to classic ERP
tion, the decision to invest in a suitable ERP Traditionally, ERP systems are based on systems. They facilitate fast data access
system is mainly driven by its benefits from centralized data storage (TR1). Thus, de- by means of the SAP HANA database. The
a process-related point of view. centralization in terms of Industry 4.0 is a horizontal and vertical integration of inter-
criterion which is hard to achieve. This is nal and external IT systems is a feature that
Based on the classification into three why classic and evolutionary ERP systems all ERP systems support by nature.
categories – classic, evolutionary, and (SAP ERP® ECC or Business Suite on AnyDB/
revolutionary – the ERP system’s degree of HANA database) only meet these criteria to
fulfillment of the requirements mentioned a small extent. Nevertheless, revolutionary
in Figure 11 will be assessed with the help ERP systems (SAP S/4HANA) benefit from
of Harvey Balls. the simplification of the data model which
32
Industry 4.0 |
Is your ERP system ready for the digital era?
PR1
Suitability for dynamic
planning, control, and execution
PR2
Support for an integrated
end-to-end process
PR3
Progressiveness of the human-
machine interaction in the process
PR4
Location-independent control
and execution of processes
PR5
Efficiency of process steps
supported by the system
PR6
Process improvement through
intelligent data analyses
Does not meet requirements Meets requirements to a small extent Meets requirements partially
Meets requirements to a large extent Fully meets requirements
Looking at the data use requirement (TR3), the ERP system’s database which will offer Assessment with regard to
classic and evolutionary ERP systems additional potential for decentralized data process-related requirements
are not mature in terms of intuition and management. The shift of the source code In fact, the assessment of ERP systems with
personalization. They are equipped with from the application to the database layer regard to process-related requirements
elementary visualization, analysis, and increases the speed of data access but correlates to the assessment with regard to
automation functionalities in the form does not yet tap the full potential. Moreo- technical requirements (see Figure 12).
of transaction-based user interfaces. By ver, SAP Fiori apps do not so far support all
contrast, SAP S/4HANA offers a much more user roles and business functions and thus
advanced mobile and role-based user ex- cannot fully replace classic transactions.
perience with the help of modern technol- This leads to the fact that there might still
ogies such as SAP Fiori and SAP UI5 which be a major development and configuration
are available out-of-the-box. effort when implementing e.g. S/4HANA,
based on special custom requirements.
It can be concluded that revolutionary ERP
systems such as SAP S/4HANA best meet Independently of the ERP system class, the
the technical requirements in terms of integration of SAP ME, SAP MII, and SAP
Industry 4.0. Nevertheless, there is still de- PCo increases the degree of fulfillment,
velopment potential in all defined criteria. especially in the area of data storage (TR1)
In future, data will still be stored centrally in and data exchange (TR2).
33
Investing in Germany | A guide for Chinese businesses
34
Industry 4.0 |
Is your ERP system ready for the digital era?
The main principle of Industry 4.0 is to Another very important aspect in Industry
increase flexibility and adaptability in 4.0 is the timeliness of data and the speed
production and logistics processes (PR1). of data access (PR5). While evolutionary
The ERP systems of all three categories ERP systems are based on new database
enable vertical integration of IT systems technologies that allow for fast data access,
from the different organizational levels in revolutionary ERP systems basically avoid
a company. Nevertheless, this may require the storage of aggregated intermediate
the development of complex interfaces and results through the use of a logically simpli-
major configuration efforts caused by e.g. fied data model. This way it is ensured that
the different communication standards of the user always works with current data.
information technologies. Vertical integra-
tion is facilitated by the use of integration The timeliness of data is mainly needed for
software such as SAP ME, SAP MII, and intelligent analysis tools (PR6) which are
SAP PCo, which connects the top floor and integrated into the core of ERP systems
the shop floor level. This way, production (S/4HANA Enterprise Management). Classic
becomes more flexible and dynamic as and evolutionary ERP systems do not offer
data can be transmitted demand-driven a variety of functionalities for data analysis
from the ERP system to the PLC and vice whereas revolutionary ERP systems are
versa. This makes possible a greater variety meant to visualize data in form of dash-
of variants at low cost. boards and provide them to the user – also
on mobile devices.
The horizontal integration of supply chain
partners (PR2) is also a traditional func- It can be said that the improvement poten-
tionality of all ERP system categories. They tial of ERP systems lies rather in the user
provide different interface standards to interaction with the system than it does
exchange data across companies but the in the integration of IT systems within and
automation of these data exchanges still across companies (PR1 and PR2). Moreover,
represents an area for improvement. process efficiency can be increased by both
the timeliness of data and the transparen-
Revolutionary ERP systems provide an cy created by different, newly integrated
efficiency gain in the area of human-ma- analysis functionalities. As revolutionary
chine interaction (PR3). While classic and ERP systems originally fulfill the majority of
evolutionary ERP systems do not provide these requirements, they have received the
intuitive data input and output technolo- highest rating in this assessment.
gies, SAP S/4HANA does with its SAP Fiori
and SAP UI5 applications. Role-based and
intuitive user interfaces help avoid errors
and increase the efficiency of control and
execution activities. This will become even
more efficient when using these function-
alities on mobile devices (PR4). The user
may use the modern data human-machine
interfaces on-the-fly on a smartphone
or tablet. This location-independent hu-
man-machine interaction enables new
processes which have not yet even been in
focus.
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Investing in Germany | A guide for Chinese businesses
Use cases:
successful
examples in the
area of ERP
Industry 4.0 is no longer in the future. The first techni-
cal innovations in the area of production and logistics
are helping to make processes more transparent and
more efficient. The following section outlines how ex-
isting technologies may be used throughout the whole
company and how they can contribute to the flexibility
of business processes.
36
Industry 4.0 |
Is your ERP system ready for the digital era?
Deloitte-M4.0-Cube:
integration of use cases
The Deloitte-M4.0-Cube , which stands for Enabler:
The Deloitte-M4.0-Cube is
Manufacturing 4.0, helps companies to plot describe technical solution opportunities
their solution space for Industry 4.0. This which facilitate the implementation of a conceptual model which
way they get an overview of their feasible Industry 4.0. The enablers are a selection
is used to plot use cases
solutions and can draw a conclusion about of technologies that facilitate the connec-
how to achieve their individual goals. tion of the physical and digital worlds. They with regard to performance
can be divided into three types. They are
layers, business functions,
As shown in Figure 13, the Deloitte-M4.0- characterized by the transformation of in-
Cube consists of the following three dimen- formation. They are distinguished between and enablers.
sions: “physical to digital”, “digital to digital”, and
“digital to physical” which are the dimen-
sions of the value loop.
Business functions: Moreover, the enabler “Digital Vision and
define the context in which the enabler is Culture” exists. It describes the readiness
applied in the company. They represent of a company to invest in digitalization and
the traditional business functions along the the visualization of processes and its will-
supply chain. ingness to implement necessary changes in
the organization.
Fig. 13 – Deloitte-M4.0-Cube
Performance
Layers
Digital Strategy
Strategic Targets
& Structure
Organizational Structures
Adva
H nc
Ad uman A ed Rob
Operational Processes Adva vanced V ugmenta otics
Smart
n c ed M is u tio
So
Clo cial Me anufaalization n
IT Infrastructure cturin
Artifi ud Com dia g
Big cial In putin
t Digita Data & telligenc g
c
u t H l In frastr A d v a e
od & Adva uman Int uctur nced Ana
Pr men ing nt nced erfac e lytics
o p r c e n g s D ig S e n sors e
ve
l u
So urem ri c Digita ital Cultu
e c tu gisti n g s l Visio r e
D oc fa Lo ti le n
Pr nu rke rsa Business
Ma Ma Afte Functions
&
les
Sa
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Investing in Germany | A guide for Chinese businesses
38
Industry 4.0 |
Lorem ipsum dolor sit amet
Project experience
visualized as
use cases
Industry 4.0 is no longer in the future. The first technical
innovations in the area of production and logistics are
helping to make processes more transparent and more
efficient. The following section outlines how existing tech-
nologies may be used throughout the whole company
and how they can contribute to the flexibility of business
processes.
39
Investing in Germany | A guide for Chinese businesses
#1 #2 #3 #4
Digital Option #1: Digital Option #2: Digital Option #3: Digital Option #4:
Logistics – operational Logistics – operational Logistics – operational Logistics – operational
processes – digital vision processes – advanced processes – Big Data and processes – visualization
and culture: sensors: Advanced Analytics The user-friendly visualiza-
The use of mobile devices Mobile devices enable the pro- Thanks to an advanced data tion of information on mobile
in warehouse management duction worker to collect phys- model a more detailed rep- devices offers the opportunity
facilitates the digitalization of ical data (i.e. stock information) resentation of production can to analyze data in real-time
business processes which pre- with the help of a scanner. be captured in the system. and to make decisions as well
viously caused a lot of manual as corrections (stock transfer
effort. postings).
40
Industry 4.0 |
Is your ERP system ready for the digital era?
#1 #2 #3
Digital Option #1: Digital Option #2: Digital Option #3:
Logistics – operational Logistics – operational Logistics – operational
processes – digital vision processes – advanced processes – visualization
and culture: sensors: The processing and subsequent
The digitalization of business Collecting position data of visualization of GPS-position
processes (logistics planning trailers using GPS enlarges the data enables a new form of
and execution) shows a living intra-company IT infrastructure. planning and executing logistics
digital culture in the company. processes.
41
Investing in Germany | A guide for Chinese businesses
#1 #2 #3 #4
Digital Option #1: Digital Option #2: Digital Option #3: Digital Option #4:
Manufacturing – knowledge, Manufacturing – operational Manufacturing – planning Manufacturing – planning
skills and culture – digital processes – advanced and controlling – big data and controlling – advanced
vision and culture sensors and advanced analytics manufacturing
The production worker is sup- Machine data such as quality The MES also serves as a The direct transfer of customer
ported by digital work instruc- information are collected by platform for Big Data analyses. orders from the ERP system
tions which are stored at MES sensors during production With the help of advanced via MES to PLC permits the
level and can be accessed on and sent to MES. This way the analytic tools such as SAP MII production of a lot size of one.
demand. production can be adjusted if there is the opportunity to With the help of technologies
quality issues occur. e.g. analyze the root causes of such as SAP PCo which serves
errors and non-conformity that as middleware between the
led to customer returns. MES and the PLC, an individ-
ualization of products is ena-
bled and changes in customer
requirements can be taken
into account during production
even at short notice.
42
Industry 4.0 |
Is your ERP system ready for the digital era?
#1 #2 #3 #4
Digital Option #1: Digital Option #2: Digital Option #3: Digital Option #4:
Sourcing and procurement – Sourcing and procurement – Sourcing and procurement – Sourcing and procurement –
planning and controlling – planning and controlling – operational processes – operational processes –
digital vison and culture Big Data and Advance cloud computing visualization
SAP Ariba enables the digitali- Analytics SAP Ariba functionalities are Thanks to a modern user inter-
zation and automation of stra- The data model used by SAP available in the Cloud which face procurement information
tegic, tactical, and operational Ariba and its built-in analyt- makes them usable at any time. is visualized role-based for the
procurement processes. ics functionalities support The technical connection to a user.
the transformation of large Cloud facilitates a more effec-
amounts of data into intelligent tive integration of supply chain
data analyses which serve as partners.
beneficial decision support for
procurement transactions.
43
Investing in Germany | A guide for Chinese businesses
Conclusion
44
Industry 4.0 |
Is your ERP system ready for the digital era?
Revolutionary ERP
is needed to increase overall flexibility and
to produce individualized products with a
lot size of one in a cost-efficient way. There-
fore, companies wanting to implement
Industry 4.0 need to consider their data
systems such as
S/4HANA are an initial
management, which data should be stored
centrally or decentrally and how modern
user interfaces might increase process
efficiency. But due to the limited number
of SAP Fiori apps not all necessary busi-
but very essential step
towards Industry 4.0
ness roles and functions are supported in
a company. Moreover, improvements are
required in the area of analytics for ERP
systems in order the better to utilize the
data collected and generated. With the
help of technology providers and users
this may be changed in the near future. To
overcome these challenges, a use-case-
based approach by the technology user
is required to help technology providers
improve their functionalities.
45
Investing in Germany | A guide for Chinese businesses
Different ways to
approach Industry 4.0
with Deloitte as a
competent partner
As revolutionary ERP systems offer the SAP SE recommends a system conversion Our cross-functional portfolio of consulting
greatest support for a flexible planning, for existing SAP ERP clients as it is easier, services allows us to also look at surround-
control, and execution in production, com- less cost-intensive and less disruptive than ing business areas which will be affected
panies need to think about how to success- a greenfield implementation of SAP S/4HA- by the change in IT. As Industry 4.0 can be
fully upgrade to SAP S/4HANA. And many NA. It still offers a majority of advantages implemented incrementally, it is advisable
roads lead to Rome. which are characteristic for the SAP S/4HA- to define use cases for the different busi-
NA technology. A greenfield implementa- ness functions and realize them one after
The possible ways to SAP S/4HANA include tion is recommended for those clients who the other. But the potential of the technical
a greenfield implementation with an ini- want to build up a completely new system. enablers is not used to a full extent until
tial data load, a system conversion, and a use cases are applied along the entire sup-
landscape transformation. For companies This is why the transition process has to ply chain. To achieve this, Deloitte may help
that already work with SAP ERP ECC 6.0 the be well thought out. Hence, companies with the identification and implementation
transition to SAP S/4HANA can be done opting for a transition should plan it wisely. of applicable use cases.
with the help of a system conversion. As Therefore, Deloitte represents a reliable
long as the system is a Unicode system, partner. We have gained vast professional But in addition to looking at process-relat-
the change from SAP ERP ECC 6.0 to SAP experience in SAP system implementations ed improvements, employees have to be
S/4HANA should work smoothly. If this is and transformations worldwide and across enabled to use the new technologies effec-
not the case, the system has to be convert- industries. Together with the client, Deloitte tively. This requires the training and qualifi-
ed into Unicode beforehand. The system analyzes and assesses the client’s IT land- cation of workers to carry out their opera-
conversion is done in one step by doing scape, identifies gaps and improvement tional tasks but also includes the need for
both a software upgrade and a change of potential, and provides advice on suitable motivation in order to eliminate the nega-
the database. information technologies for the client’s tive aspects of resistance to change. Only
business. After the selection of technolo- if the workers support the change in the
The system conversion can be either done gies, Deloitte may also assist in the imple- company can efficiency and flexibility gains
from the SAP ERP ECC or Business Suite mentation, configuration, and operation of be achieved. Therefore, Deloitte offers
on any database to SAP S/4HANA directly them. change management and human resource
or by splitting it into the migration to the consulting services to the client to best
HANA database and afterwards the system prepare employees in the company for the
conversion to SAP S/4HANA or with anoth- upcoming innovations.
er intermediate step to S/4HANA Finance.
When deciding in favor of the intermediate
step to SAP S/4HANA Finance the logistics
processes will not be simplified right away
but can be added later on when converting
to SAP S/4HANA Enterprise Management.
Figure 15 shows the road to SAP S/4HANA.
46
Industry 4.0 |
Is your ERP system ready for the digital era?
5
1
4
3a
SAP S/4HANA
Enterprise
Management
3b
HANA
SAP S/4HANA database
Finance
2
1 3b
any HANA
database database System Conversion from any From HANA database to SAP
database to SAP S/4HANA S/4HANA Finance via Add-on
2 4
System Conversion from any System Conversion from
database to HANA Database S/4HANA Finance to SAP
(Data Migration) S/4HANA Enterprise
Management
3a 5
System Conversion Greenfield
from HANA database to SAP S/4HANA
SAP S/4HANA Enterprise
Management
47
Investing in Germany | A guide for Chinese businesses
Contact
Peter Dengel
Director
Tel: +49 (0)62 27899 0523
pedengel@deloitte.de
Authors
Christian A. Hochmuth
Christoph Bartodziej
Carolin Schwägler
Contributors
Dr. Volkmar Rudolf
Katharina-Elise Viehhauser
Lukáš Pokorný
48
Industry 4.0 |
Is your ERP system ready for the digital era?
49
Deloitte refers to one or more of Deloitte Touche Tohmatsu Limited, a UK private
company limited by guarantee (“DTTL”), its network of member firms, and
their related entities. DTTL and each of its member firms are legally separate
and independent entities. DTTL (also referred to as “Deloitte Global”) does not
provide services to clients. Please see www.deloitte.com/de/UeberUns for a
more detailed description of DTTL and its member firms.
Deloitte provides audit, risk advisory, tax, financial advisory and consulting
services to public and private clients spanning multiple industries; legal advisory
services in Germany are provided by Deloitte Legal. With a globally connected
network of member firms in more than 150 countries, Deloitte brings world-
class capabilities and high-quality service to clients, delivering the insights they
need to address their most complex business challenges. Deloitte’s more than
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Issue 06/2017