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A picture containing sitting, white Description automatically generated.

A picture containing sitting, white Description automatically generated.

1 0 1 1 1 o 1 1 1 1 1 1 1 1 o 1 Collect When production starts Mll picks up the counter values (i.e. Yield, Scrap and Unscheduled downtime are the actual data collection elements) from the different sensors across shop floor connected to OPC server throug SAP Report Data collected are reported to OEE against active order and later gets posted to SAP ECC as process order confirmation and goods movement Analyze production data collected from machines are analyzed in real-time to derive OEE and related KPIs which helps to identify bottleneck and improve performance o 1 1 1 o.

Manufacturing Performance Management & Execution.

Manufacturing Performance Management & Execution – Custom Enhancements.

Overall LiteMES Functionalities. Emergency Process Order Creation - Emergency Order creation functionality will enable ability to create process order against existing process order during ERP outages. On ERP availability, user can send an SAP order from ECC and assign the emergency order to the SAP order. After assignment, all the data collections and goods movements reported against the order are sent to ECC against the SAP order. Business Continuity Planning : Custom application in MII to handle critical business transactions during ERP outages (BCP). Unit ID Creation & Assignment - UnitID based execution (serial number/batch) helps in WIP tracking and continuous visibility as well as genealogy tracking of product being manufactured Order Execution – OEE handles the process order execution from starting to closing of order. Automatic & Manual Parametric Data Collection ( Yield,Scrap,Downtime etc.) -The automatic collection of data including yield, scrap and downtimes from machines to SAP OEE at real-time is enabling accurate KPIs, calculations and avoid any kind of data loss. In Process Quality Inspection -Quality inspection along with Quality notification and SPC analysis functionality have been developed on SAP OEE integrated with SAP QM module for real-time quality inspection recording and analysis for in-process inspection Order Confirmation - Auto Confirmation feature in OEE ensures closure of process order and reporting of order quantity . Custom KPI/PPI -OEE KPIs such as availability, performance, quality are now providing a very clear and useful measure of the performances and effectiveness of the manufacturing processes, resources and mechanism by which the process can be optimized Material Stock Transfer - The Stock display and Transfer user interface allows the user to transfer the stock of a particular material from one storage location to a different storage location Production Goods Consumption and Reversal -Goods consumption and reversal functionality helps the factory users to consume goods, perform a reversal, and also display report of goods movement performed against a production or process order. This activities can also be performed during ERP outage and automatically scheduler will trigger the messages to ERP once its up Production Goods declaration and Reversal - This functionality allows users to do goods declaration with an auto-generated Unit ID, Storage Unit Number and Shelf Life Date against the quantity of the selected order. This activities can also be performed during ERP outage and automatically scheduler will trigger the messages to ERP once its up.

Architecture Overview. Image result for packaging line can counter machine.

Custom Database. . . SAP ERP. SAP PCo. SAP OEEINT.

SAP MM-IM. SAP MII/OEE. SAP PP. SAP QM. PROCESS FLOW.

Overall Business Benefits. SAP OEE based solution implemented by IBM is a key steppingstone to achieve Industry 4.0 and Digital Transformation in production which will help to realize financial benefits in terms of reduced downtime costs, repair costs, quality costs and increased labor efficiency and productivity. Custom application in MII to handle critical business transactions with minimum clicks during ERP outages (BCP). UnitID based execution (serial number/batch) helps in WIP tracking and continuous visibility as well as genealogy tracking of product being manufactured The automatic collection of data including yield, scrap and downtimes from machines to SAP OEE at real-time is enabling accurate KPIs, calculations and avoid any kind of data loss. OEE KPIs such as availability, performance, quality are now providing a very clear and useful measure of the performances and effectiveness of the manufacturing processes, resources and mechanism by which the process can be optimized. Real-time interaction with shop-floor machines/sensors through OPC server and monitoring of critical shop-floor control parameters such as temperature, pressure, unscheduled downtime values is a key step towards Client Industry 4.0 and Smart Factory initiative. Enabling automatic data collection is helping the client to avoid erroneous data reporting, paperwork and any kind of data inconsistencies. Custom role-based access to different dashboard actions like Edit Downtime, Report Downtime, Yield, Scrap reporting, Order Start/Stop additionally helps business to grant privilege only to authorized users. Automatic scheduler based retry mechanism for failed messages due to ERP outage. Automatic scheduler-based closure of different business operations including confirmation posting, order restart, shift closure, downtime posting helps business to avoid errors due to manual operations. Emergency Order creation helps in BCP scenario management in shop-floor to handle critical transactions during ERP outages. Its a solution to manage order execution so that users don’t feel the difference of availability of ERP during BCP scenarios and can continue the production execution as-is.

Need a single platform for integrating disparate MES applications with SAP ERP & EWM Monitor and manage the plant performance along with production labor data capture and analysis Need a system for BCP scenario management in shop-floor to handle critical transactions during ERP outages.

Image result for SAP ERP icon. Image result for LIMS icon.

Solution Walk-Through.

[Audio] Hi I am ( Production supervisor)I manage the shift and oversee production. Let me check My Dashboard. I need to dispatch some orders for execution.

[Audio] Let me enter quantity to release Let me release with this button so that operator can view and execute these orders for production.

[Audio] Let me check order for this shift. Let me filter by Order Number. I can also filter by status, order number , material , material description and UNITID. Let me check this progress Bar to understand whether additional input material is required in the staging or not After Selecting the order I can see Start order and some other button is active now. I can also create UNITID for the quantity of the order released by clicking the Unit id button.

[Audio] Hi I am ( Production operator) Let me start my Day's work Let me click on Manage order button Let me click on operator dashboard tile to reach my dashboard.

[Audio] Let me Check the orders status I can see New Order & Active Order Great !!! Let me start one order. I can see Unit Id is not assigned to that particular order I can click UNITID button for Unit Id creation Unit ID created , Let me click here to start Order Let me enter the start Date , crew size and select target status. After this operation status will be changed to NEW to ACTIVE By clicking in Details button I can see the activities of the order with date time.

[Audio] There is not enough stock in staging area. Lets bring the material Let me click on this Stock transfer button. I can also do it from main dashboard Let me click on Display button to check all the available material stock in other location Let me put some quantity here. Let me click on Transfer.

[Audio] We have sufficient quantity in staging , Let me do a good Issue Let me click on Goods Issue button I can see all Orders with Header Material. Let me select one PO Let me put Quantity Let me click on consume button Let me see Goods Movement Report button to check the consumption details The stock is now updated in ECC and MII.

[Audio] ERP is down. Let me still do some Goods Issue Now ECC is down and I can see status of BCP as ON Let me put Quantity Let me click on consume button As ECC is down now so I can see the message in queue monitor in failed status. Now ECC is up and Goods Movement is sent to ECC now..

[Audio] ECC is down. Let me still do some Goods Receipt Now ECC is down and I can see status of BCP as ON Let me put Quantity Let me click on Declare button As ECC is down now so I can see the message in queue monitor in failed status. Now ECC is up and Goods Movement is sent to ECC now..

[Audio] I have some doubts in this order, so let me just create new inspection for this operation so that I can track like whether that particular incident passed or failed Ohh!!! ALERT got generated .I have not done quality inspection for this order. Let me inspect the Quality/ quantity I can see new inspection point has created. I think I should not pass this. I should put some comment also in comment section so that other Operator/supervisor can also track that defect and can pass that inspection once that issue get resolved Let me select the fail option Let me save it Let me record the Inspection results by clicking on submit button.

[Audio] Let me create one new Inspection point. I can see new inspection point has created. I can see the range is 5- 15 Oho!!! Result is outside range. Let me put it. As its fail so I need to give some remark Let me save it Let me submit it.

[Audio] Let me report produced good quantity , rework , quantity loss etc Confirmation is now sent to ECC.

[Audio] Let me report data collection at machine level Let me click on SAVE button.

[Audio] Let me hold the order due to some operational break down Let me report an unscheduled downtime Now operational breakdown taken care let me close downtime Downtime is closed now..

[Audio] I can resume this order again by clicking on the resume button after the break.

[Audio] Let me update today's production I can see all Orders with Header Material, By-product, Coproduct material. Let me select first order Let me Specify Quantity and UOM I can also see SLED and Production Date and Posting Date. Let me Declare it. I have declared wrong amount. Let me correct it Let me click on the Reverse button.

[Audio] Great Now I can monitor the overall performance of particular operation.

[Audio] Hi let me complete the operation for order. I need to click on this Complete button when I complete the execution of the operation Let me enter date and time of completion in this popup screen I can see status changed from active to completed..

[Audio] Hi I need to track the Rework, Yield Quantity, Scrap Quantity and Temperature for one UnitID. Ok I have one Unit id report through that I can do it easily. Let me scan the Unit ID I can see Order and Material and Storage Location details for my Unit ID. Let me select the row. I can see thedata Collections performed against that Order and Operation in the graph.

[Audio] ECC is down now. Let me continue with Emergency Order Let me create Emergency orders Let me provide start date and end date and Emergency Order is now created. I can continue with this order aduring ERP outage..

[Audio] I can see New Emergency Order . Let me start one Emergency order Let me click on Manage order button and start Emergency Order Okay !!! After starting the Emergency Order the status changed from NEW to ACTIVE.

[Audio] Emergency Order is now active. Lets issue some component materials Let me put Quantity Let me click on consume button.

[Audio] Lets perform declaration Let me put Quantity Let me click on declare button Let me click on info button to see the pie chart.

[Audio] Let me report some data collection for emergency order Let me check the pie chart in Emergency Order report to see the overall data collection and goods movement done against the emergency order.

[Audio] ECC is up now.Let me assign Emergency Order with SAP Order Let me complete the assignment of emergency Order with SAP Order After assignment Emergency Order is now completed and I can continue with SAP Order which is now active.

[Audio] Now I can continue with my SAP Order All the Data collections and good got against Emergency Order is now assigned to SAP Order Let me check the chart in Emergency Order report All the data collections and goods movement got assigned to SAP Order and also sent to ECC.

[Audio] Thank You. Thank You. Manufacturing Performance Management & Execution.