sap mii implementation at dätwyler - sap...
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SAP Mii Implementation at Dätwyler
SAP Digital Manufacturing
30th of May 2017 Stepan PickaHead of Applications
Dätwyler IT ServicesPolní 224, 504 01 Nový Bydžov, Czech Republic
stepan.picka@datwyler.com, www.datwyler.com
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1 Short introduction: Dätwyler
2 The need for change
3 Our way to SAP MII
6 Our success story: What did we achieve with SAP MII?
4 Building the business case
Agenda
5 Selection of the right partner
Dätwyler:
Stability & strength of a large industrial group
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Swiss origin, established in 1915
50 operative organizations worldwide
20 manufacturing sites
Revenues around CHF 1,200 million
Listed on the SIX Swiss Exchange:
Dätwyler HoldingDätwyler IT
Services
Dätwyler Sealing
Solutions
Dätwyler Technical
Components
Dätwyler Cabling
Solutions
Organizational
Structure
Key Facts
99,25 €
125,00 €
147,20 € 148,70 €153,00 €
90
100
110
120
130
140
150
2012 2013 2014 2015 2016
Sto
ck
pri
ce
(m
ax
. va
lue
)
Year
International presence with more than 8‘000 employees
worldwide
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Dätwyler Group
5
Products
Industries
ICT- & FTTx Networks
Safety Cabling
Building Automation
Systems
Medical Devices
Brake Systems
Liquid Sealing
Applications
Building Construction
Electronic & IT Devices
Automation Products
Measurement
Technology
Dätwyler Cabling
Solutions
Dätwyler Sealing
Solution
Technical
Components
Commercial &
Non-Commercial Online
Distribution
Health Care
Automotive
Consumer Goods
Civil Engineering
Communication-
Engineering
Electrical Engineering
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2 The need for change
3 Our way to SAP MII
6 Our success story: What did we achieve with SAP MII?
4 Building the business case
Agenda
5 Selection of the right partner
1 Short introduction: Dätwyler
Key factors starting the change
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DSS Healthcare
Sensing and manipulation
of the production process
Supervisory Control & Data Acquisition
Monitoring supervisory and Automated
control of the production process
Workflow, recipe control to produce
desired end products,
optimizing production
Establish plant schedule production,
material use, delivery and shipping,
inventory
Manufacturing
Control
SQL
Database
SAP ERP
80% own developed
Level 4
Level 3
Level 2
Level 1
Current landscape not compliant with ISA 95
SAP (global) Switzerland
Local MES USA India Belgium Italy
High dependencies on single system
Dependency on 1
single person and
internal know how
No supplier
Non supported HW
Windows 2003
Servers / SQL 2000
Outdated IT
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2 The need for change
3 Our way to SAP MII
6 Our success story: What did we achieve with SAP MII?
4 Building the business case
Agenda
5 Selection of the right partner
1 Short introduction: Dätwyler
Shop floor assessment
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Disparate manufacturing systems
Dependency on SAP for manufacturing operations
Legacy MES – unscalable
Problem
statement
Site visits
Stakeholder interviews
Study of current landscape – MES
& SCADA
Requirements workshop
Assessment
Current state analysis
document
As-Is
process map
Analysis
Product evaluation
Fitment analysis products &
requirements
Product validation with key
stakeholders
Solution Fitment Analysis
Stage 1
Pre-screening of
MES products
based on
dimensions &
criteria
Stage 2
Detailed
assessment
based on user
requirements and
ISA-95 framework
Solution Fitment
Analysis SnapshotURS document
Advice
High level architecture
Cost & benefit analysis
Solution roadmap
Sample scenario demonstration on
recommended MES platform(s)
Benefit analysis
High level
architectureSolution roadmap
Results of the tool selection
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Pros
Cons
Wonderware
Archestra
Leveraging current
investments in plant
automation
Good integration capabilities
with L2 & L4 systems
Deep knowledge in
automation technology
Open integration platform
enables broad interoperability
& real-time information flow
Modular architecture of MES
solution
High licensing costs
Rockwell Factory
Talk
MES solution comes with
extensive experience in multi-
site implementations
Support for local, centralized
or mixed deployments over
multiple sites with high
localization capabilities
Huge installed base of
industrial automation
customers
Deep knowledge of
automation technology
Highest licensing costs
Lower level of interfacing
advantage with L2 & L4
systems compares to
Wonderware Archestra
SAP MII
Significant lower licensing
cost
Can be seamlessly
integrated with SAP ERP
Ability to meet the needs of
Dätwylers divisions
Full fledged MES
solution can be
developed to manage
production
Meet reporting needs
Meets reporting needs of
Dätwyler through one
common system
Lack of configurable, out of
the box functionalities
focusing on MES
Being a development
platform may have a higher
cost associated with
services, lead time for
implementation &
subsequent support
Expected Benefits of SAP MII
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Improved metrics &
KPI monitoring
Reliable and faster OEE calculation with wide range of real time data availability (only
for linked equipment)
Improved productivity analysis to identify root cause of failures, to reduce breakdowns
and enhance quality
Reduces
dependency on
SAP & local MES
MES decouples shop floor from SAP and hence impact of SAP outages reduces
significantly
Reduces the effort required to restart the whole systems after every SAP outage
Smoother plant operation and reduced inconveniences due to SAP outages
Enhanced
customer
satisfaction
Singe & reliable source of data on customer orders
Improved customer order traceability across shop-floor
Enhanced capability to handle and resolve customer complaints
Reduced manual
effort / Enhanced
employee
engagement
Reduced paper based data acquisition
Faster, easier data acquisition and analysis to leading to effective root cause analysis
(eliminate waste, scrap & downtime)
Reduction in manual data entry effort
More user friendly User Interface (UI)
SAP simplification SAP customizations will be minimized making future maintaining of SAP less costly
SAP upgrade cost will be lower
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2 The need for change
3 Our way to SAP MII
6 Our success story: What did we achieve with SAP MII?
4 Building the business case
Agenda
5 Selection of the right partner
1 Short introduction: Dätwyler
„The electric light did not come from the continuous improvement of candles.“
Oren Harari
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Facts for the IT community
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ISA-95
Manufacturing
Control
ERP
MES
Current landscape compliant with ISA 95
SAP (global) Switzerland
Local MII
serverUSA India Belgium Italy
Low dependencies on single system
Newest standards
Supported HW
Windows 2012
Servers / SQL 2008
Global supplier + internal team
More
independency as
well as global
supply
Additional facts used to sell the project
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More homogeneity will improve manageability of heterogeneous manufacturing system environment
Higher efficiency due to less entry errors, strong central ERP & better growth management
Better distant asset control by removing obsolesce systems, especially in case of acquisitions
Transformation to a digital factory
Faster performance by moving to zero paper-based on barcode scans & non-productive time reduction
Embedded analytics will support daily & local operations with real time analytics and KPIs
Better traceability by automated batch san from the shop floor back to the ERP system
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2 The need for change
3 Our way to SAP MII
6 Our success story: What did we achieve with SAP MII?
4 Building the business case
Agenda
5 Selection of the right partner
1 Short introduction: Dätwyler
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Motivation of our choice for the implementation partner
Movilitas was recommended by SAP in different countries
Many successful projects (since 2004) with SAP Manufacturing platform
SAP-certified SAP MII Rapid Deployment Solution (RDS) based on ISA95
standards (best practice), accelerating the deployment up to 40% because the
data model comes out-of-the-box
Largest specialist player in this space in Europe (> 40 MII consultants)
Global presence to support deployments (Belgium, France, Germany, USA)
Reference visits/calls with satisfied customers/reference
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1 Short introduction: Dätwyler
2 The need for change
3 Our way to SAP MII
6 Our success story: What did we achieve with SAP MII?
4 Building the business case
Agenda
5 Selection of the right partner
Prototype for Alken as a start
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Replacement of SAP PI sheets
Communication with Scada system
Mobility for line clearance
Recipe management
Roadmap & first achievements
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Roadmap
First
achievements
2017 2019Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q2 Q3 Q4Q4Q2 Q3 Q1
Belgium
China
2016 2018
USA 1
USA 2
India
Italy
Q1
Belgium India China
Processes accomplished Processes accomplished Processes started
Weighing Carousel
Mixing Extrusion
Moulding Trimming
Inner packingSteam
sterilization
Weighing Omniflex
Mixing
Weighing Color Service
Mixing Washing
Processes started
Moulding Trimming
Vision Omniflex
Lessons learned
2121
Scope definition
Availability of key people within the organization
Dependency on other suppliers
Interaction between external parties
Project
management
Technical
integration
Setup of MII landscape
Setup of mobile devices
Connections using to Archestra using Kepware
Connections to scales from Metler Toledo
China Case: Integration with 586 presses
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3.500 PO’s per day
25.000 labels printed per day
10.000 IDocs per day
28.000 RFC calls per day (MII-SAP)
5.000 picking movements in warehouse
Alken Case: Washing and Mixing
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Team spirit and cooperation with Movilitas
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Full transparency, flexibility and cooperation
Movilitas = extension of our own team
Support with recruitment and training for
internal MII team
Strategic partnership with Movilitas
I am happy to answer your questions!
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