sap manufacturing industry forum 2014fm.sap.com/data/upload/files/janicki sap-plm-ectr final.pdf ·...

SAP Manufacturing Industry Forum 2014, Itasca, IL 16-Apr-2014

Tim van Horn - Janicki / Reinhard M. Staebler - CENIT 1

1

PROPRIETARY

1

Rapid Deployment of a Multi-CAD Solution for SAP PLM 7Tim Van Horn, Janicki IndustriesReinhard M. Staebler, CENIT North America, Inc.

SAP Manufacturing Industry Forum 2014April 15-16, Itasca, IL

2

PROPRIETARY

2

Contents

• Company Overview

• Where did we come from?

• System Selection Process

• SAP PLM Implementation

• Tool Integration Platform

• New SAP Process

• Lessons Learned

• Next Steps



3

PROPRIETARY

3

Company Overview

4

PROPRIETARY

4

Composite Fabrication Parts & Tools

Proprietary

Family owned and operated since 1993



5

PROPRIETARY

5

Manufacturing Facilities

Washington• 5 Buildings• 6 large 5-Axis NC Mills• Autoclave• Clean Room

Utah• 1 Building• 3 Large 5-axis NC Mills• Adjacent to Hill AFB• Temp, Humidity Controlled• Trim & Drill, high volume

6

PROPRIETARY

6

Large-scale

High-precision

5-axis CNC machining

Composite fabrication

Exotic Metal fabrication

Autoclave, Ovens

NC Cut, Trim & Drill

Manufacturing Capabilities

AUTOCLAVE

WATER JETS

OVENS

PLY CUTTERS

5‐AXIS NC

COMPOSITE FAB

EXOTIC METALS



7

PROPRIETARY

7

Where did we come from?

8

PROPRIETARY

8

Business Process Overview

SalesPlan

DesignProcure Build Test

Deliver

QUOTE CASH

Project Centric

Boeing Wing Tool

Production

Supply Chain

Sales CRM

Financial

Raw Materials Facilities

Human Capital

Machines

Mills

Data Mgmt

Project Mgmt

ContractsOrders

Organization& Roles

PeopleTrainingCertificationsPerformance

Payroll

Mfg ProcessCapacityQuantityMaintenance

LocationAvailabilityCribsCells

InventorySuppliersRaw MaterialRequisitionsQuotesContracts PO’sLead Time

ReceivablesPayablesLedgerAssetsAccountingBudgetingReporting

CustomersOpportunitiesForecastingEstimatingPricing

SchedulingControlJobs

Single Source of dataConfiguration ControlRole based AccessSystem Administration

ShippingToolsInstructions

Deliverables

Input

Parts ListItem Master(Bill of Material)QuantitiesMaterial

BOM

PayrollStatementsComp.Benefits

SourcingRecoveryExpeditingItem MasterTransfersPick List

PayrollStatementsComp.Benefits

Vendor dataCustomer dataFinancial dataProduction dataPeople data

ERP System

This image cannot currently be displayed.

Dashboards

Critical Skills

Tools



9

PROPRIETARY

9

Previous Design Data Control ProcessLots of documents in Windows Folders

“BOM”

2D Dwgs3D Model

FEM

Approve

Designer

By Program

By Customer

Boeing787

By Project By Subproject“Deliverable”

6791.rwrkDwg

By Pattern.

Naming convention keeps things synchronized.

By Industry

Aero

Alpha name Alpha nameAlpha name 10377

10377.0110377.01.10100

ModelFEM

Sub‐project

Folder LandFolder LandFolder Land

Parts List BOM

“Excel”

“Primavera”BOM & TOC

“PDF”Drawing

Pointers QCBDQCBD

Class III

WorkOrders

10

PROPRIETARY

10

System Selection Process



11

PROPRIETARY

11

Motivation to implement PLM and ERP

• Pursue Production Aerospace Parts business which requires AS9100 certification which requires improved data management system and processes.

• Support the continued growth of the company.

12

PROPRIETARY

12

PLM Business Objectivesnot just turn on a PLM system

1. Higher productivity of design project teams

2. More secure storage of important documents

3. Improve proficiency of people’s time

4. Create Single Source of Data (Find it, Use it, Trust it)

5. Accelerate innovation

6. Find data faster, less frustrating, more efficient

7. Improve reuse of JI standard parts and processes

8. Pass AS9100C 7.3 certification

9. Higher quality, less rejections

10.Have fun working together



13

PROPRIETARY

13

PLM Selection Criteria - Why SAP?

1. Integration with an ERP system

2. Integration with CATIA

3. Integration with NX

4. Integration with MSOffice, Windows

5. Ease and speed of use

6. Project centric (not just part no.)

7. Workflow

8. Data Import / Export

• Best of Breed• Industry Leader• R&D Spending• Adherence to Standards• Open Architecture

14

PROPRIETARY

14

SAP PLM Implementation



15

PROPRIETARY

15

Full management support from owners to VPs, and managers.

Project Managers

DesignTeams

OpsManagers

ManufacturingEngineersSales

Finance / Accounting

Subject Matter Experts (SMEs)Lend expertiseSupport actions

Steering Team(Advisory)

Weekly

VP BIS

• Criteria• Status / Advice• Remove Road Blocks• Decision

ImplementationTeam (Status, Issues)

Weekly

SAP Program Manager

• Execute plan• Status & Issues• Action Items• Training

HR Procurement

Daily scrum

1. Responsible for outcome2. Set Objectives, Goals, and Scop3. Business Issues4. Effort and expenditures5. Risk management6. Scope control7. Reconcile differences in Opinion and approach

1. Define and execute the plan2. Host status and issues meetings3. Project Management4. Accountable to Steering Team for

completion of the project.

16

PROPRIETARY

16

May June July Aug Sept Oct Nov Dec

Project Prep

BluePrint / Realization

Gap Analysis

Integration Testing

End User Training & New Projects Startup

Rest of SAP Go Live

1/2/2014

Project PlanProject TeamScope

System Build & ConfigurationValidation of Fit/GapsRICEFW DevelopmentUnit and String TestingIntegration TestingUser Acceptance & Performance TestingLevels 2 and 3 SAP Training

Process DesignRequirementsSpecsFunctionality

• Strategy was: New and Revised.• So, new projects were started up on SAP.• Old projects finished in existing systems.• No data conversion, except on demand.

PLM Implementation Roadmap

GO Live9/5/13

OriginalPlan7/15

2013



17

PROPRIETARY

17

May June July Aug Sept Oct Nov Dec

Project Prep

BluePrint / Realization

Gap Analysis

Integration Testing

End User Training & New Projects Startup

Rest of SAP Go Live

1/2/2014

Project PlanProject TeamScope

System Build & ConfigurationValidation of Fit/GapsRICEFW DevelopmentUnit and String TestingIntegration TestingUser Acceptance & Performance TestingLevels 2 and 3 SAP Training

Process DesignRequirementsSpecsFunctionality

• Strategy was: New and Revised.• So, new projects were started up on SAP.• Old projects finished in existing systems.• No data conversion, except on demand.

CENIT/DSC brought CAD – ECTR to rescue the implementation

GO Live9/5/13

OriginalPlan7/15

2013

CENIT/DSC

18

PROPRIETARY

18

SAP software is composed of several modules that support major company departments. Below shows the 17 SAP module names and the department it supports. All modules are integrated and use the same single source of data.

1 2 3

4 5 6

7 8 9

0 .

C

=

- + *

÷

E

SalesProjectManagement

Design

Inventory

Manufacturing

Testing & Non Conformance

Shipping

1. SDSales &Distribution

2. CRMCustomer RelationshipManagement

3. PSProjectSystems 4. PLM

ProductLifecycleManagement

5. DMSDataManagementSystem

6. ECTREngineeringControlCenter

7. MMMaterials Management

8. WMWarehouse Management

9. PPProductionManagement

10. MESManufacturingExecutionSystems 11. QM

Quality Management 12. FI/CO – Finance & Control = Finance

13. HCM – Human Capital Management – HR,14. KABA & 15. CATS – Time collection16. Payroll – Pay checks17. DMS – Document Management System

SDSales &Distribution

Suppliers (SCM)

Janicki Departments

17 SAP Modules

DMS



19

PROPRIETARY

19

Design, NC Programming, Analysis

SAP‐DMS

2D Dwgs3D Models

FEMeBOM

Create Parts &

AssembliesNotification• Team• Project Title• Number

SOWSOW

From Sales

Customer Data• 3D Models

Other Data• Regulations• Specifications• Standards

Release

Workflow Project Manager Mfg Engr QA OPS

CATIA File Name: 12345.12.12345_description

.DXFIGES

Document Info RecordSAP DIR # xyzabc xxx yy

TypeItem No. Rev

• One part per model

From Project Manager

Random sequential no.

In WorkDesign Review

Approval Review Released In Active ObsoleteAccessible

Start Work

xyzabc xxx yy

12345.12.12345_description

Input from Project

Manager

TheThe CATIA files start out with a formatted file name but when checked into SAP they get the SAP sequential number. When files are brought out of SAP their file names are the original formatted name.

SAPECTR

Scope of PLM Implementation

20

PROPRIETARY

20

Solution Scope

• CAD Integration with Engineering Control Center• CATIA• NX

• Document Management• Status Network• Release, Storage, Control

• Data Exchange• Visualization• Change Master• BOM and Material Management• Project Systems (PS) through object links

• Delayed until Phase 2• NC machine files• Engineering Change Management• Workflow



21

PROPRIETARY

21

SAP PLM Infrastructure

Sedro-Woolley

VEGTREXECC Content/Cache

Hamilton

Layton

100 Mbps MPLS24ms Latency Content/

Cache

5 CATIA Users8 NX Users

50 CATIA Users70 NX Users

1 Gbps Fiber Optic<1ms Latency

22

PROPRIETARY

22

Tool Integration PlatformEngineering Control Center



23

PROPRIETARY

23

Tool Integration PlatformEngineering Control Center

• Recent SAP announcement that Engineering Control Center has been selected as the future Tool Integration Platform for all CAD systems SAP Engineering Control Center

• Consistent integration of authoring tools along the value chain

• 360 degree product view including mechanics, electronics, software …

24

PROPRIETARY

24

Engineering Control Center (ECTR)“A Companion to the CAD Designer”



25

PROPRIETARY

25

Integrated Business Processes in SAP

INT

EG

RA

TIO

NC

OL

LA

BO

RA

TIO

N

C O

N S

O L

I D

A T

I O

N

TD

M/P

DM

People

ServiceManufacturing MarketingSourcing

Solutions

Engineering

Global Backbone

Process

AU

TO

MA

TIO

N

mCAD and CAE

eCAD and SW

Digital Planning

SupportingDocuments

SAP Engineering Control Center

26

PROPRIETARY

26

Engineering Control Center (ECTR)

• Flexible, user-specific folder structures

• Access to any type of document

• Context sensitive pull-down menus in clear text

• Colors and symbols show a lot of information at a glance

• Drag & Drop, Copy & Paste

• Access to many different SAP objects



27

PROPRIETARY

27

ECTR: Toolbars & Context Sensitive Menus

● E.g. edit DIRs using the tool bar or the context menu.

● Cockpit for SAP:Accessing standard and customer specific “transactions“

● Access to SAP GUI, SAP PLM 7, PPM, …

28

PROPRIETARY

28

ECTR Assemblies View

CAD structure can be expanded and reviewed



29

PROPRIETARY

29

ECTR Bill Of Materials View

E-BOM and M-BOM can be expanded and reviewed

30

PROPRIETARY

30

View Object in Desktop and Object Browser

• Detailed access to folder content

• The tool bar offers several folder operations

• The Object Browser has a bar with several folder display options



31

PROPRIETARY

31

DIR in Desktop and Object Browser

1 Both windows have a tool bar for DIR operations

2 The DIR is now in the selected folder

3 The Object Browser displays tabs for metadata

2

1

3

32

PROPRIETARY

32

Object Browser – Basic Data

• Displays SAP metadata

• Click to enable edit mode in the Object Browser



33

PROPRIETARY

33

ECTR 3D Viewer (VE integration)

3D rendering of CAD structure can be reviewed and analyzed without CAD license

34

PROPRIETARY

34

Siemens NX8

ECTR operation and function are integrated inside NX Menus and toolbars to provide communication with SAP



35

PROPRIETARY

35

Dassault Systemes CATIA V5

ECTR operation and function are integrated into CATIA Menus and toolbars to provide communication with SAP

36

PROPRIETARY

36

New SAP Process



37

PROPRIETARY

37

While other applications create data the PLM assumes the role of file access and saving through embedded commands.

Private Files

WORD

EXCEL

CATIA UG

Sales

iPhone

DROID

WEB

EXCEL PDF

PowerPoint

PLM Users with Multiple Applications

Engineering

Procurement Finance, HRMfg PlanningProject Managers

Primavera WORD

EXCELPowerPoint

PrivateFolders / Files

PrivateFiles

PrivateFiles

PrivateFiles

ServerMeta-Data Managed Files

PLM System

Functional View of a PLM System

PLM

Read, Write, Queries, Changes, Work-Flow. Versions, Approvals

As easy as drag and drop.Fancier QCBDEasier to Use then Folder Land.

MSOFFICE integration

38

PROPRIETARY

38

The Design Document Status Network



39

PROPRIETARY

39

Lessons Learned

40

PROPRIETARY

40

Lessons Learned – Selection and Startup

1. Know your existing processes before starting

2. Get clear on your selection criteria

3. Understand the Implementation Plan.– Does the plan make sense?

– e.g., avoid mid month go live

4. Find consultants with knowledge & experience– of the SAP PLM landscape

– in your area of focus (e.g. CAD).

5. Start Blueprint early



41

PROPRIETARY

41

Lessons Learned PLM Processes1. Do SME training early before implementation2. Have a training environment3. Keep status network simple4. Plan for production testing

• Test end-to-end lifecycle process• Fully test system with real data and user roles

5. Staggered start of PLM ahead of ERP6. As-needed, on-demand, limited, PLM, data migration7. Plan for Post go-live support

• This is where real training gets done and issues get fixed.

42

PROPRIETARY

42

Next Steps



43

PROPRIETARY

43

Objectives & goals helped prevent Scope Creep

Phase 1 Go-Live and Stabilize

9 months

Maintain 90% Revenue

Pay employees

Open system

Critical processes

No workflow

Minimal custom reports

Phase 2 Complete & Enhance

After Phase 1

Fully realize goals

Incremental releases

QA & Workflows

Reports, KPIs

Optimize

Dashboards

Mobile

E-recruiting

Jan “14 Dec“14

44

PROPRIETARY

44

Our SAP PLM Implementation Partners

www.cenit.com

[email protected]

www.dscsag.com

[email protected]



45

PROPRIETARY

45

Thank You

Tim Van HornJanicki [email protected]

Reinhard M. StaeblerCENIT North America, [email protected]