이효상 이사SAP Korea

맞춤형 할리 6시간 생산 비결SAP Connected Manufacturing 을 활용한 생산정보 통합 및 최적화

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맞춤형할리를 6시간만에생산하는비결Harley Davidson Motorcycles 소개

회사명 Harley-Davison 설립 연도 1903 (Wisconsin, USA)

회사소개미국의 대형 Motorcycle / Accessories 제조

Heavyweight (over 750 cc) motorcycle 생산

매출액 $4.2 billion / 2013

종업원 수 6,300명

2012년

Connected

Plant

구축 결과

2012년 York, PA 공장에 최초 적용

SAP APO 통합(딜러 계획오더, 생산 순서, 생산지시서 등)

ME to APO로 리포팅 포인트 자동 연계

모든 작업일정 및 상세 정보는 SAP 통하여 단방향 업데이트(예외 사항 발생시 만 machine에서 APO 로 정보 업데이트)

Recipe steps, Work Instruction, shop order data 정보POD에 자동 display

예외 사항 발생 시 공정 step을 bypass 기능을 Station에 제공

SAP MII를 활용한 Real time data 통합

Pco*를 통한 OPC 데이터 ME로 통합 및 SAP parameter정보를 shop floor OPC’s로 전송

•* Pco: Plant Connectivity(SAP가 제공하는 현장 설비 데이터 인터페이스 모듈)POD: Production Operation Dashboard

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맞춤형할리를 6시간만에생산하는비결Harley Davidson Motorcycles 시스템아키텍처

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맞춤형할리를 6시간만에생산하는비결New Concepts in ME for Automotive - Non-interactive display

Non-interactive display to the operator

On screen work list updated automatically through tool interaction

Operator interaction only required to handle exceptions

© 2015 SAP SE or an SAP affiliate company. All rights reserved. 5

맞춤형할리를 6시간만에생산하는비결New Concepts in ME for Automotive - Recipe Steps

Expected and actual torque values(Data Collection)

Data to collect associated to an assembled component(Assembly Point)

Standard work step triggered from tooling

Recipe steps to list the work required at an operation

• Recipe steps defined based on the configuration of the vehicle

• Ability to bypass a recipe step if the work cannot be completed

POD Touch screen

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맞춤형할리를 6시간만에생산하는비결Sequenced Orders

Orders released by sequence Based on run rules, orders must be processed in sequence based on the

calculated schedule

Production orders created and sent to the production floor as lots of 1 – no two bikes on the production line are the same

Day 1

Model Mix

Production line 1

A) No two

in a sequence

Day 2

© 2015 SAP SE or an SAP affiliate company. All rights reserved. 7

맞춤형할리를 6시간만에생산하는비결Key Development

Order management

WIP start

Assembly

WIP completion

• APO-ME 인터페이스를 통한 마스터/계획정보 통합• 작업오더는반드시 SAP에서지정된순서에의해릴리즈• 후속오더정보사전에통보

• POD 화면을 통한 터치스크린 방식 필요 정보 제공(오더 시작/공정/Batch)

• 표준작업정보외에실시간으로 Update 정보함께제공

• MII 시스템을 통한 현장 “Pick to right” 정보 실시간 인터페이스• Recipe을 통한 ME용 상세공정 정의 및 POD를 통한 공정 관리• Genealogy 정보 제공(Serial, batch NO.)

• APO & ME 간실시간 WIP 정보교환• ME에 validation 기능 제공(Recipe 준수 or Exception of bypasses)

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맞춤형할리를 6시간만에생산하는비결Sequenced Orders

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맞춤형할리를 6시간만에생산하는비결Harley-Davidson York Manufacturing Factory - 동영상

Smart Factory 구현 사례: “Harley Davidson”

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맞춤형할리를 6시간만에생산하는비결Harley-Davidson York Manufacturing Factory - 동영상

© 2015 SAP SE or an SAP affiliate company. All rights reserved. 11

Business Strategies Transformation:Combining Business Realities with Networks

Connect Products, Assets and

Manufacturing to

Product Networks

Personalized Solutions

Gain real-time network insights with

Machine Networks

Improve People’s Lives

Transform Supply Chain and

Logistics into

Demand Networks

Customer Centricity

© 2015 SAP SE or an SAP affiliate company. All rights reserved. 12

Connected Manufacturing:전사적운영정보와제조현장실행정보간의통합

ERP

SFAC

MOM(제조운영관

리)

SFAC

MES

SFAC(제조현장 자동화설비)

ERP

분리된 시스템 구조 통합된 정보 흐름

글로벌 기업 운영

MES – Manufacturing Execution SystemsSFAC – Shop Floor Automation and Control MOM– Manufacturing Operation Mgnt.

© 2015 SAP SE or an SAP affiliate company. All rights reserved. 13

Connected ManufacturingLeveraging Big Data to drive new insights into operations

Connect

Transform

Reimagine

Continuous

Intelligence

Operational

Efficiency

Reduced

Cost

SAP HANA Platform Smart devices

Multi-structured data sources

Social and mobile External systems

Visualization

Mobile users

Tag

Improved

Quality

© 2015 SAP SE or an SAP affiliate company. All rights reserved. 14

SAP Connected Manufacturing StrategyCloud / On-Premise / Shop Floor

Pow

ere

d b

y SA

P H

AN

A

Process & Production Planning

Logistics

public cloud

SAP MII

on-premise

SAP FIORI

SAP Manufacturing Execution Suite (SAP ME, SAP MII, SAP PCo)

Manual Data Entry Automatic Data Entry (Machine Connectivity)

Shop F

loor

LIMSMES SCADA / HMIPlant DataCollection

Wireless Integration

EnvironmentalBuilding Management

Plant HistorianPlant DB

DCSPLC

Cloud fully integrated with on premise investments

private cloud

Predictive Maintenance

Sensors

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SAP Connected Manufacturing 을위한다섯가지시나리오

SCADA / HMI

Machine

Layer

ME / MII

ERP

1

2

3 E-Commerce

Consumer

3

1

Service

Provider Machine Cloud

4

4

Supplier 5

5 Scenarios

Shop Floor to Top Floor

Machine to Machine

e-commerce Integration

Machine Cloud

Direct Replenishment

1

2

3

4

5

Networks

© 2015 SAP SE or an SAP affiliate company. All rights reserved. 16

What is SAP Connected Manufacturing ?

»Customers requirement is to have package that enables this process

(Historian/MES/ERP) for Look Back, Predictive, and Process Execution Control.

»SAP Connected manufacturing helps to “Look Forward” and

“Suggesting Resolutions” to problems and Drive changes into the processes

by looking forward

© 2015 SAP SE or an SAP affiliate company. All rights reserved. 17

SAP Connected Manufacturing:The Smart Factory for manufacturing networking

DESIGN PLAN RESPOND PRODUCE DELIVER OPERATE

Connectors

ERPProduction plan Bill of materials (BoM)

Variant management Production steps

Serial Numbers Quality results per lot

Order confirmation

Production details management

Detailed and flexible

Production step routing

Log parametric data

Tolerance checks

Return „conformance

Mapping of ME production details to PLC control parameters (recipe)

Sensor detects material carrier

Requests control parameters

Collect, validate, record, take action

PLC

(Machine)Machine reports completion and

requests next operation

ME &

MII

PCo

P

a

c

k

a

g

e

© 2015 SAP SE or an SAP affiliate company. All rights reserved. 18

SAP Connected Manufacturing Solution

Equipment

Effectiveness

Production

Enforcement

and Execution

Manufacturing

Performance Product Quality

Monitoring &

Analytics

Product

Networks

Production

Traceability

Process

Optimization

Manufacturing

Execution Suite

Cloud Platform

S/4 HANA

© 2015 SAP SE or an SAP affiliate company. All rights reserved. 19

공장정보통합관리를위한 SAP MII 솔루션:전사적운영관점과제조현장간의효율적인연계를위한솔루션

SAP NETWEAVERO

the

r S

AP

Bu

s. S

olu

tio

ns

SA

P

BI

SAP ERP

실시간

제조현장

대시보드

Manufacturing Integration

Manufacturing Intelligence

Manufacturing Integration (통합) :

전사 비즈니스 프로세스와의 통합을 위해 SAP와실시간 현장시스템(MES, SFAC, Legacy)을연계하는 솔루션

Manufacturing Intelligence (지능화) :

이벤트, 경고, KPI에 대한 시각화 및 대시보드를통해 제조 담당자의 의사결정을 지원하는 실시간분석 엔진

SAP MII 솔루션은 전사레벨의 ERP 시스템과

제조현장레벨의 설비시스템간의 실시간 통합과

현장과 업무 프로세스의 지능화된 연계를 지원함

© 2015 SAP SE or an SAP affiliate company. All rights reserved. 20

공장정보통합관리를위한 SAP MII 솔루션:솔루션 overview: ERP와연계한제조현장관리플랫폼

Business Logic Services

Visualization

Quality Engine

KPIs/Metrics/Alerts

Data Services

Manufacturing Integration & Intelligence

PLAN MAKE DELIVER

ERP SCM PLM

LIMS

MES SCADA

Plant DataWireless

IntegrationEnvironmentalBuilding Mgnt.

HistorianDCS/PLC

INTEGRATION

Distributor/Customers

Supplier/Contract Manufacturer

Performance Management

Worker UIs

Plant Connectivity

Manufacturing Analytics

SAP ERP Business Process Simplification

© 2015 SAP SE or an SAP affiliate company. All rights reserved. 21

공장정보통합관리를위한 SAP MII 솔루션:How do we get data

Agent PCo

OPC DA 2.05a, 3.00 (note 1) O

OPC A&E 1.10 (note 1) O

OPC UA 1.00 (note 1) O

OPC HDA 1.20 (note 1) O

Socket O

OLEDB O

ODBC O

File Monitor O

AspenTech IP 21 Native O

GE Proficy Historian Native O

Citect SCADA Native O

OSISoft PI Native (PI SDK) O

OSISoft PI Native (AF SDK) O

Note: Requires OPC Server from a 3rd Party. Most commonly used are from Kepware, MatrikonOPC,Rockwell Software, Siemens. Any other OPC Server that exposes the interface versions listed are fully supported.

© 2015 SAP SE or an SAP affiliate company. All rights reserved. 22

공장정보통합관리를위한 SAP MII 솔루션:Day in the Life of Plant in-charge

Plant PerformanceMonitoring

Production &Monitoring

Breakdown Management

QualityManagement

UtilityMonitoring

ImprovedPlantPerformance

ObjectiveDecisions

Real timevisibility toOperationalExcellence

Managementby exceptions

ExpeditedActions

ImprovedEquipmentAvailability

Reduced cost of Maintenance

ImprovedDeliveryPerformance

ImprovedProductQuality

ExpeditedbatchClearance

ReducedEnergy andUtilityConsumption

© 2015 SAP SE or an SAP affiliate company. All rights reserved. 23

공장정보통합관리를위한 SAP MII 솔루션:Day in the Life of Plant in-charge - Plant Performance Monitoring

Control cockpit Plant view KPI monitoring

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공장정보통합관리를위한 SAP MII 솔루션:Day in the Life of Plant in-charge – Maintenance Management

Auto Maintenance Notification creation Breakdown Management

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공장정보통합관리를위한 SAP MII 솔루션:Why SAP MII ?

1. ERP를 포함한 제조현장의 다양한 시스템간의 정보 통합을 통한 가시성 확보

2. 시스템간의 정보의 Single Version of truth 확보

3. 제조현장 작업자들을 위한 편리한 UI 제공

4. 비즈니스 로직 서비스에 의한 코딩(coding) 없는 Graphic 인터페이스 제공

5. SOA 개념의 개발플랫폼 기반으로 제조현장 시스템간의 연계 및 개발이 빠름

6. 다양한 제조현장 설비와의 정보를 통합하고 단일화된 KPIs, Alerts, Metrics 제공

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공장정보통합관리를위한 SAP MII 솔루션:주요고객현황

조립산업;a

식품산업오일&가스/화학산업

제약산업 철강산업

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SAP Manufacturing Execution(ME):솔루션 overview

SAP Manufacturing Execution

» 제조, 현장 운영 관리 및 컨트롤

» 비즈니스 시스템과 제조 현장 간의 통합

» 글로벌 운영을 위한 Component와프로세스 추적성 제공

Manufa

cturing Funct

ionalities

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SAP Manufacturing Execution(ME)Integrated Solution Overview

Manufacturing Execution

LIMS

Wireless Integration

Historian

PLC

SAPMEINT(MII)

Plant Connectivity

MM PM PP QM

SCMPLM ERP

Process Control

Standardized Work

As-Built Record

Paperless

As-Built History

TraceabilityWork-in-Process

Work InstructionSCADA

/ HMI

Equipment

Data

© 2015 SAP SE or an SAP affiliate company. All rights reserved. 29

SAP Manufacturing Execution(ME)“Out of the Box” Contents

MDE Integration (PCo)

Configuration Management

In-Process Monitoring, Control and SPC

Recipe Management

Non Conformance Management

Tool Management

Floor Stock Location & Reservations

Time Sensitive Material

ERP Integration(Data and Transactional)

Electronic Work Instructions

WIP Reporting

Sampling & Test Plans

Labor Tracking and Charge Codes

Engineering Change Management

Traceability and Genealogy

Time Management

Shift Management

Parametric Data Collection & SPCDashboards

Resource Status and Plant Maint.Message Board and Alerts

Scheduling, Queueing

KPI Management (OEE, ..)

Skill Certification and Buy off

© 2015 SAP SE or an SAP affiliate company. All rights reserved. 30

SAP Manufacturing Execution(ME) Integrated Solution Overview

Master Data Authoring and Engineering Change Management

Enterprise Resource Planning

Quality Management

Inventory Management

Production Planning & Shop Floor Dispatcher & Monitoring

Manufacturing ExecutionWIP Tracking and Genealogy (Order, Lot, and Serial #)

Manufacturing Process Control

Defect Tracking and Resolution

Data Collection

Labor Tracking

Plant Maintenance

• Order Create/Update• Production Order (Production)• Product Serial Number• Quality Inspection Lot• Scheduling

• Planned Order (Repetitive)• Service Order (RMA)• Network Order (Production)• Variant Configuration (Production)

• Material• Material Classification (Custom Data)• Long Material Number

• Routing• Work Center Category• Work Center & Capacities – ME Resource• Quality Inspect Character (100% & <100%)• Equipment Scheduled Down• BOM• Phantom Component• Alternate Component• Co & By-Product

• HR User w/Certification• Work Instruction (DMS Document)• Inventory• Shop Order Reservation• Material – Batch Managed• Storage Locations

• Yield Confirmation• Production Order – all reporting steps• Planned Order – last operation only• Variant Configuration – all reporting steps

• Scrap Confirmation• Production Order – any step• Planned Order – any step

• Rework Confirmation• Production Order

• Order Close• Production and Planned Order• Service Order• Parent Batch Number

• Goods Movement• Production/Planned Order Back-flush• Component Goods Movement• Serial/Batch Number (Components)

• DC Batch and Batch Characteristics• Routing• Quality Notifications• Quality Inspection• QM Evaluation of Inspection Character• ME Evaluation of Inspection Character

• Equipment Unscheduled Down & Usage• Inventory• Return, Scrap, Unreserved• Storage Location Movement

SAPMEINT Interfaces

© 2015 SAP SE or an SAP affiliate company. All rights reserved. 31

SAP Manufacturing Execution(ME)Why SAP ME ?

ERP Integration “out of the box”

Controls Production of every single unit (Lot Size 1)

Unit Level Tracking & Tracing / Genealogy

(What operation, tool or machine was used, where parts came from, etc.)

Highly effective and easy to use interfaces defined for touch screens

Comprehensive nonconformance management including in-line sampling

Role specific access and personalized dashboards for operators

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SAP Manufacturing Execution(ME)SAP ME – 상세기능(Control)

Manufacturing BOM Routings

Certifications Floor Stock Management

Alternate Operations Conditional Routing

Automatic Actions

Routing Logic

Sequential Operations

Nested Routings

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SAP Manufacturing Execution(ME)SAP ME – 상세기능(Tracking and Traceability)

As-Built Summary Device History Record (DHR)

Audit Log Component Usage

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SAP Manufacturing Execution(ME)산업별고객현황

;aConsumer

ProductsO&G / Chem Life Sciences

Mill Products and

MiningUtilities

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SAP Manufacturing Execution(ME)산업별고객현황 - 계속

Aerospace

Defense

;a

Automotive High Tech IM&CMedical

Device

© 2015 SAP SE or an SAP affiliate company. All rights reserved. 36

SAP Manufacturing delivers….

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감사합니다