Saha / Syamsunder / Chakraborty Manufacturing Performance Management using SAP OEE

Implementing and Configuring Overall Equipment Effectiveness
1. ed
ISBN: 978-1-4842-1150-2
Verlag: Apress
Format: PDF
Kopierschutz: 1 - PDF Watermark

E-Book, Englisch, 353 Seiten

Learn how to configure, implement, enhance, and customize SAP OEE to address manufacturing performance management. Manufacturing Performance Management using SAP OEE will show you how to connect your business processes with your plant systems and how to integrate SAP OEE with ERP through standard workflows and shop floor systems for automated data collection. Manufacturing Performance Management using SAP OEE is a must-have comprehensive guide to implementing SAP OEE. It will ensure that SAP consultants and users understand how SAP OEE can offer solutions for manufacturing performance management in process industries. With this book in hand, managing shop floor execution effectively will become easier than ever. Authors Dipankar Saha and Mahalakshmi Symsunder, both SAP manufacturing solution experts, and Sumanta Chakraborty, product owner of SAP OEE, will explain execution and processing related concepts, manual and automatic data collection through the OEE Worker UI, and how to enhance and customize interfaces and dashboards for your specific purposes. You'll learn how to capture and categorize production and loss data and use it effectively for root-cause analysis. In addition, this book will show you:Various down-time handling scenarios. How to monitor, calculate, and define standard as well as industry-specific KPIs. How to carry out standard operational analytics for continuous improvement on the shop floor, at local plant level using MII and SAP Lumira, and also global consolidated analytics at corporation level using SAP HANA. Steps to benchmark manufacturing performance to compare similar manufacturing plants' performance, leading to a more efficient and effective shop floor. Manufacturing Performance Management using SAP OEE will provide you with in-depth coverage of SAP OEE and how to effectively leverage its features. This will allow you to efficiently manage the manufacturing process and to enhance the shop floor's overall performance, making you the sought-after SAP OEE expert in the organization. SAP OEE is a packaged solution on SAP's Manufacturing Integration and Intelligence module. It was developed by SAP as a lite-MES for process industries. SAP OEE-which stands for Overall Equipment Effectiveness-provides the dashboards and analytics integrated with the SAP ERP and HANA platform to enable production personnel to get real-time data recording and monitoring of the production process. It also provides a configurable framework to enhance and customize solutions based on business needs.

Dipankar Saha works for IBM India as IT Architect & Service Delivery Lead for SAP Manufacturing. He has co-authored several books on SAP MII & ME and regularly participates in different public forums/events/seminars presenting papers on topics related to SAP Manufacturing. He has worked on several SAP MII, OEE & ME implementation projects globally defining solution architecture and managing solution deliveries. Previously he worked for SAP Labs India and was involved in the design and development of SAP MII. Dipankar is a SAP Certified Associate Enterprise Architect. He has around 14 years of experience in the IT industry and has a Bachelor's of Technology Degree in Chemical Engineering.Mahalakshmi Syamsunder is a Manufacturing solution consultant currently working for IBM India. She has contributed to solution consulting for various manufacturing and utility clients. She also carries a deep expertise in shop floor automation and was involved in Design, development, training and implementation of projects on SAP MII, ME, OEE and plant automation. Mahalakshmi has a Bachelor's Degree in Electronics and Communication Engineering, and a Master's in Technology Management. She has 5 years of experience in automation space and over 7 years of experience in SAP Manufacturing
Sumanta Chakraborty is an experienced professional with 18+ years of cross-industry experience in various roles. A Mechanical Engineering graduate from NIT - Durgapur, India, he started his career in automobile manufacturing and gradually moved into the development of Enterprise Software products around Manufacturing, ERP and Supply Chain Management. Last 12+ years Sumanta is with SAP Labs India Bangalore, and is currently in the role of SAP OEE Product Owner having end-to-end Product Management Responsibility at global level.  He works with SAP customers and partners across the globe with team spreading across continents. Sumanta is very well known in the SAP Manufacturing eco system.

Autoren/Hrsg.

Saha, Dipankar

Syamsunder, Mahalakshmi

Chakraborty, Sumanta

Inhaltsverzeichnis

1;Contents at a Glance;4
2;Contents;6
3;Foreword;12
4;About the Authors;14
5;Acknowledgments;16
6;Introduction;18
7;Chapter 1: Manufacturing Performance Management: An Overview;20
7.1;Need for KPIs to Optimize Manufacturing Performance;20
7.2;Benchmarking and Target Setting;22
7.3;OEE Standard and Its Calculations;23
7.4;The Need for an Effective Operator Interface for Data Collection;26
7.5;Shop-Floor to Top-Floor Integration;27
7.6;Summary;29
8;Chapter 2: SAP OEE: A New Product for Manufacturing Performance Management;30
8.1;SAP OEE on MII platform;30
8.2;Solution Architecture of SAP OEE;31
8.3;SAP OEE: Product Overview;34
8.3.1;SAP OEE Functional Model;34
8.3.2;SAP OEE Add-on Component in ECC;36
8.3.3;SAP OEEINT for Integration of ECC and OEE;38
8.3.4;SAP OEE Operator Dashboard (Worker UI);38
8.3.5;SAP OEE Reporting and Analytics;40
8.4;SAP OEE: Benefits;41
8.5;Summary;41
9;Chapter 3: The SAP OEE Add-on Component of ERP;42
9.1;OEE Master Data in ERP;42
9.1.1;Shift Configurations;43
9.1.1.1;Configure Shift Grouping;44
9.1.1.2;Configure/Maintain Shift Definitions;45
9.1.1.3;Configure/Maintain Shift Sequence;45
9.1.1.4;Associate Shift with Work Center Capacity;46
9.2;OEE Configuration Data in ERP;48
9.2.1;Data Collection Category;49
9.2.2;Data Element Type;50
9.2.2.1;Data Element Type Configuration: Reported Element;51
9.2.2.2;Data Element Type Configuration: Calculation Element;52
9.2.3;Data Element;53
9.2.3.1;Data Element Configuration;53
9.2.4;Data Collection Contexts;54
9.2.4.1;Data Collection Contexts Configuration;55
9.2.5;Data Collection Element;55
9.2.5.1;Data Collection Elements Configuration;55
9.2.6;Hierarchy Node Classification;58
9.2.6.1;Hierarchy Node Classification Configuration;58
9.2.7;Machine Groups;58
9.2.7.1;Machine Groups Configuration;59
9.2.8;Production Modes;59
9.2.8.1;Production Modes Configuration;60
9.2.9;Production Activities;60
9.2.9.1;Configure Production Activities;61
9.2.10;KPI Configuration;61
9.2.10.1;KPI Configuration;62
9.2.11;Hierarchy Model in OEE;63
9.2.12;Global Hierarchy;64
9.2.12.1;Global Hierarchy Template Configurations;64
9.2.12.2;Defining Node Type;65
9.2.12.3;Global Hierarchy Configuration;69
9.2.12.4;Benefits of Global Hierarchy;72
9.2.13;Plant Hierarchy;72
9.2.13.1;Plant Hierarchy Template Configuration;72
9.2.13.1.1;Node Type as Plant;74
9.2.13.1.2;Node Type as Area;74
9.2.13.1.3;Node Type as Team;75
9.2.13.1.4;Node Type as Line;76
9.2.13.1.5;Node Type as Machine;77
9.2.13.2;Plant Hierarchy Configuration;78
9.2.13.3;Details Tab;79
9.2.13.4;KPI Targets tab;82
9.2.13.5;Classification Tab;83
9.2.13.6;Standard Rates Tab;83
9.2.13.7;Bottlenecks Tab;84
9.2.13.8;Machine Groups Tab;86
9.2.13.9;Technical Objects Tab;86
9.2.13.10;Node Delete;88
9.2.13.11;Reason Codes;88
9.2.13.12;Global Reason Codes;90
9.2.13.13;Plant Reason Code Configuration;93
9.2.13.14;Upload Plant Reason codes;94
9.3;ALE Customizing Settings in ERP for Integration with OEE;96
9.3.1;ALE Customizing Settings in ERP for Communication with MII;97
9.3.1.1;Define RFC destination;97
9.3.1.2;Logical System for ALE;101
9.3.1.2.1;Logical System Configuration;101
9.3.1.3;Partner Port;102
9.3.1.4;Partner Profile Configuration;103
9.3.1.4.1;Message Type;106
9.3.1.4.2;IDoc Type;106
9.3.1.5;Customer Distribution Model;107
9.3.1.5.1;Customer Distribution Model Configuration;107
9.4;Summary;109
10;Chapter 4: SAP OEEINT for Integration of ECC and OEE;110
10.1;Configuration Templates for OEEINT;112
10.1.1;SAP OEE NetWeaver Configuration CTC;113
10.1.2;SAP OEE Integration Configuration CTC;115
10.2;OEE Integration Configurations;120
10.2.1;Global Configurations;120
10.2.2;Supported Plants Configurations;121
10.2.3;IDoc Message Listener Configurations;122
10.2.4;Processing Rule Configurations;123
10.2.5;Scheduler Configurations;123
10.2.6;Workflow Configurations;125
10.2.6.1;Lifecycle Methods of Standard Workflow;126
10.2.6.2;Enhancing Standard OEEINT Workflow;127
10.2.7;Transfer of Data from ERP to OEE;128
10.2.7.1;Transfer of Master Data and Transfer of Material/Work Centers;129
10.2.7.2;Transfer of OEE Master Data and Transfer of Plant Hierarchy/Reason Codes;130
10.2.7.3;Transfer of OEE Configuration data;131
10.2.7.4;Queue Monitor;134
10.3;Summary;135
11;Chapter 5: OEE Configurations in SAP MII;136
11.1;User Roles and Authorizations;136
11.1.1;User Roles for SAP ERP;136
11.1.2;User Roles for OEE Integration Services in SAP MII;137
11.2;SAP OEE CTC Wizards;138
11.2.1;SAP OEE Configuration CTC;139
11.2.2;SAP OEE Migration CTC;141
11.3;SAP MII Configurations for SAP OEE;144
11.3.1;Display ERP System Data;146
11.3.2;General Configuration;148
11.3.2.1;Dashboard Assignment to User Group;148
11.3.2.2;User Administration in SAP OEE;148
11.3.2.3;Dashboard Assignment in OEE;149
11.3.2.4;Customization Configuration;151
11.3.2.5;Reason Code Configuration;152
11.3.2.6;Extension Configuration;154
11.3.3;Activity Configuration;156
11.3.3.1;Activity Configuration Options;157
11.3.3.2;Example to Create an Activity;158
11.3.3.3;Standard OEE activities;160
11.3.4;Order Status Description Configuration;160
11.3.5;Order Dispatch;160
11.3.6;Scheduled Downtime Maintenance;161
11.3.6.1;Create Scheduled Downtime;162
11.3.6.2;View Existing Scheduled Downtimes;162
11.4;OEE Configurations Transport;162
11.5;Summary;163
12;Chapter 6: SAP OEE Dashboard;164
12.1;Dashboard Configuration;164
12.1.1;Dashboard Configuration Elements;164
12.1.2;OEE Dashboard Description Tab;165
12.1.3;Dashboard Section Content;165
12.1.4;Dashboard Buttons;165
12.1.5;Dashboard Button Options;166
12.2;Types of OEE Dashboard;166
12.2.1;Plant Monitor Dashboard;166
12.2.2;Line Monitor Dashboard;167
12.2.3;Operator Dashboard;168
12.2.3.1;Dashboard Selection;170
12.2.3.2;Line or Work Unit Selection;170
12.2.3.3;Shift Selection;171
12.2.3.4;Current Shift Order;171
12.2.3.5;Current Shift KPIs;172
12.2.3.6;Line Availability Summary;172
12.2.3.7;Top Downtimes;173
12.2.3.8;Dashboard buttons: Manage Orders;174
12.2.3.9;Dashboard buttons: Manage Downtimes;179
12.2.3.9.1;Minor Stoppages;180
12.2.3.9.2;Machine Breakdowns;182
12.2.3.9.3;Line Down;183
12.2.3.9.4;Shared Downtimes;184
12.2.3.9.5;Create Shared Downtimes;185
12.2.3.9.6;Flow Time;185
12.2.3.10;Dashboard buttons: Report Production;186
12.2.3.11;Dashboard buttons: Report Speed Loss;186
12.2.3.12;Dashboard buttons: Report Standard value parameter;187
12.2.3.13;Dashboard buttons: Review Order;188
12.2.3.14;Dashboard buttons: Review Shift;188
12.3;Standard Functionalities of SAP OEE;189
12.3.1;Download and Release of Order-Operation;190
12.3.2;Execution of Order-Operation, Which Includes Start, Hold, and Complete an Order;190
12.3.3;Order Downtime Tagging;192
12.3.4;Four KPI Calculations in Real-time;192
12.3.5;OEE KPI Calculation;193
12.3.6;Goods Movement in OEE;195
12.3.6.1;Goods Receipt;196
12.3.6.2;Goods Issue;196
12.3.6.2.1;Backflush of Components;196
12.3.6.2.2;Manual Goods Issue Trigger from OEE;197
12.3.7;Update Order Confirmation and Goods Movement to SAP ERP;198
12.3.8;Real-time Monitoring of Shop Floor through OEE Dashboard;199
12.3.9;Near Real-time Replication of OEE Transaction Data to HANA;200
12.4;Summary;202
13;Chapter 7: SAP OEE Customizations;203
13.1;OEE Custom Actions;203
13.1.1;Custom Actions for OEE Shop-Floor Data Collection;204
13.2;OEE Data Model;207
13.2.1;Data Model Flow for Events;208
13.2.2;Data Flow for Order Run;209
13.3;Customizing OEE Configuration Data;210
13.3.1;Customizing Production Activity;210
13.3.2;Customization of OEEINT Workflow Configurations;215
13.3.3;Customization Scenarios of OEE Extensions;216
13.3.4;Access Global Context from Standard SAP OEE Dashboard;217
13.3.4.1;Prerequisites;217
13.4;SAP MII–Based OEE Analytics;218
13.5;Customization Scenarios in SAP OEE;218
13.5.1;Scenario 1: Manufacturing Automation Systems’ Integration with SAP PCo and SAP MII;218
13.5.1.1;Prerequisites;219
13.5.2;Scenario 2: Shop-Floor Data Buffering in SAP MII;222
13.5.3;Scenario 3: Custom Extensions in SAP OEE Dashboard;224
13.5.3.1;Develop BLS Transaction for Custom Extension;224
13.5.3.2;Create a Custom Activity;225
13.5.3.3;Configure Custom Extension;225
13.5.4;Scenario 4: Custom SAP OEE Dashboard;226
13.5.5;Scenario 5: Calculate and Monitor Custom KPI;229
13.5.5.1;Prerequisites;229
13.5.6;Scenario 6: QM Notification Handling;233
13.6;Industry Use Cases for SAP OEE;236
13.7;Summary;243
14;Chapter 8: Additional features of SAP OEE Management;244
14.1;Creating PM Notification from Worker UI;244
14.1.1;Prerequisites;245
14.1.1.1;Customization Configurations;245
14.1.1.2;Activity Configurations;245
14.1.2;Report Notification in Manage Downtime;246
14.1.3;Create PM Notification;247
14.2;Line-Specific Alerts;249
14.3;Data Collection at Machine Level;250
14.4;Manual Correction of Order Execution Data;251
14.5;Visual Icons and Customer Logo in the Dashboard;252
14.6;Data Maintenance through CSV/XML Upload;254
14.6.1;Data Maintenance of Reason Codes through CSV Upload;254
14.6.1.1;Upload of Reason Code to OEE;255
14.6.2;Data Maintenance of Downtimes through CSV Upload;255
14.6.2.1;Upload of Downtimes in OEE;256
14.6.2.2;Upload of Reason Code in OEE Add-on;256
14.7;Quick Setup of a Demo SAP OEE Plant without Having an ERP Connection;257
14.7.1;SAP OEE Demo Plant Master Data Setup CTC;257
14.7.2;SAP OEE Demo Plant Order Data Setup CTC;259
14.8;Download and Reuse the Standard UI Code for Customization;259
14.9;Application Launch Pad for Goods Movement;260
14.9.1;Configurations Required to Use the Goods Movement App Customization Configuration;261
14.9.2;Activity Configuration;261
14.9.3;Activity Options to Configure the Goods Issue App;262
14.9.4;Activity Options to Configure the Goods Receipt App;263
14.9.4.1;Dashboard Configuration;265
14.9.4.1.1;Configure the Application Launch Pad;265
14.9.4.2;Goods Movement Process;265
14.9.4.2.1;Goods Issue;265
14.9.4.2.2;Goods Receipt;268
14.9.5;Use Case for Goods Movement;270
14.10;Summary;270
15;Chapter 9: SAP OEE: Reporting and Analytics;271
15.1;Real-Time Dashboards: Worker UI (Dashboard) and Plant Monitor;272
15.2;Local Plant-Level Reporting;274
15.3;Global Consolidated Reporting at the Corporate Level with SAP HANA;279
15.4;Summary;290
16;Appendix;291
16.1;Section 1: Automated Data Collection;291
16.1.1;SAP OEE Service Interface: SAP OEE Integration;292
16.2;Section 3: Customization Configuration In General Configurations;316
16.3;Section 4: Standard Activity Configuration;321
16.4;Section 5: Extension Configuration;328
16.5;Section 6: Global Context;342
16.5.1;Sample XML View Code;345
17;Glossary;347
18;Index;350