sap mii implementation at dätwyler - sap...

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

[email protected], 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

3

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

4

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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Agenda



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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Agenda



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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Agenda



„The electric light did not come from the continuous improvement of candles.“

Oren Harari

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Facts for the IT community

14

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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Agenda



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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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Agenda


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

23

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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