2904_Guided_Structure_Synchronization.pdf

Handover to Manufacturing

Guided Structure Synchronization

Martin BachmannSolution Management SAP PLM

SAP AG

© SAP AG 2011. All rights reserved. / Page 2

Agenda■ Today’s challenges in

synchronizing engineering

and manufacturing

■ Solution approach

■ Demo

■ Wrap-up


Function / Requirement CAD-BOD-eBOM mBOM-Routing Production Order Asset

Structure

Structures along the Value Chain

Idea ConceptRequire-

ment

Detail

Design

Product

Validation

Process

Planning

Process

ValidationMRP Source

Produce /

AssembleDeliver

Product Development MFG Planning ServiceManufacturing

#

#

#

GSS

eBOM = Engineering BOM

mBOM = Manufacturing BOM


Engineering Structure Manufacturing Structure

Challenges in the transition from engineering

to manufacturing

Function versus assembly sequence

Engineering version versus effectivity in manufacturing

Organizational separation of development and manufacturing

Manufacturing differences at different sites

Bike

Frame

Gear shift

Brake

Handle bar

Saddle

Front wheel

Rear wheel

Shift lever

Derailleur

Bike

Frame

Brake

Handle bar

Saddle

Front wheel

Rear wheel

Shift lever

Derailleur

Bowden cable

Bowden cable


Reference via CS07

Extract of currently implemented solutions at

Customers

CS07

The plant-independent BOM (eBOM) is referenced via transaction CS07 into a plant-

specific BOM (mBOM).

Problem: both BOMs cannot be changed independently. If there are multiple plant-

specific BOMs, this means, that the product is build the exact same way in each plant.

Copy via CS01/CEWB

CS01

CEWB

The plant-independent BOM is copied via transaction CS01/CEWB into a plant-specific

BOM.

Problem: both BOMs are completly independently. If the plant-independent BOM is

changed, all plant-specific BOMs need to be updated manually.

Copy, Sync via CN

CS01 /

ECN

The plant-independent BOM is copied via transaction CS01/CEWB into a plant-specific

BOM. Changes are synchronized via a detailed description within the change number.

Problem: both BOMs are completly independently. Even if there is a detailed description

of the changes to be implemented into the plant-specific BOM, it is still manual work.

No plant-independent BOM There is no plant-independent BOM documented within SAP. The plant-specific BOM is

created from scratch or via a Team Data Management (TDM) integration.

Problem: there is no end-to-end change management process possible. No clear

defined, reliable and compliant documented Engineering BOM available.

Manual

input,

integration

of TDM

system

SAP standard

SAP standard

Customer Solution

Customer Solution

CS01

TDM integ.


Solution Approach


Process steps

Product

Manager

Engineering

Responsible

Manufacturing

Responsible

2) Release

(“GSS” ready)

3) Plan Sync

AND

4) Restruc-

ture, resolve

conflicts

6) Finish/

Release

EC

N1

Change

status of

ECN

Sync Unit

Create a

sync unitM

CN

1

1) Create /

Update E-

BOM

5) Additional

MFG

planning


Process steps

Product

Manager

Engineering

Responsible

Manufacturing

Responsible

2) Release

(“GSS” ready)

3) Plan Sync

AND

4) Restruc-

ture, resolve

conflicts

6) Finish/

Release

EC

N1

Sync Unit

MC

N1

1) Create /

Update E-

BOME

CN

2

MC

N2

Loop back with change management usually

5) Additional

MFG

planning


How it works

Engineering

Bike

Frame

Wheel

Tire

Rim

Manufacturing

Bike

Frame

Tire

Rim

Version A

Version B

Version C

02 / 2007

02 / 2008

03 / 2009

Handover

Compare

03 / 2009

2.0

2.0

Sync Unit


How it works

2.0

2.0

2.0

1.0

1.1

1.2

1.3

ECN01 – 1.1.09

ECN02 – 1.2.09

ECN03 – 1.3.09

ECN04 – 1.4.09

ECN05 – 1.5.09 2.0

1.0

1.2

MCN01 – 1.1.09

MCN03 – 1.3.09

MCN05 – 1.5.09

Bike

Frame

Wheel

Tire

Rim

Bike

Frame

Tire

Rim

Engineering Manufacturing


Engineering System

mBOM

System landscape, scenario 1

Synchronization will be made in Engineering system.

Manufacturing System (Plant 1)

CAD-BOD-eBOM

mBOM-Routing


mBOM

mBOM-Routing

GSS



eBOM

Engineering System

CAD-BOD-eBOM


Synchronization will be made in Manufacturing system.

mBOM-Routing

GSS


eBOM mBOM-Routing

GSS


One central System

CAD-BOD-eBOM



mBOM-Routing

GSS

CAD

System

Team Data

Mgmt.


SAP SCM (APO)ERP System

CAD-BOD-eBOM



mBOM-Routing

GSSCIF

mBOM-Routing


Synchronize (initial)

copy to target and compare

t1 t2 t3 t4 t5 t6

1

1

2

2

1 2

3

3

3

410

20

30


t1 t2 t3

1

1

2

1 2

10

20

30

1

3

Released, mature to handover

in work, not yet mature to handover


t1 t2 t3 t4 t5 t6

1

1

2

2

1 2

3

3

3

410

20

30


t1 t2 t3 t4 t5 t6

2

3

3

3

410

20

30

1

3

Released, mature to handover

in work, not yet mature to handover

1

1

2

1 2

Synchronize (ongoing)

copy to target and compare


t1 t2 t3 t4 t5 t6

1

1

2

2

1 2

3

3

3

410

20

30


t1 t2 t3 t4 t5 t6

2

3

3

3

410

20

30

1

1

2

1 2

Change Numbers within synchronization

EC

N 1

EC

N 2

EC

N 3

EC

N 4

EC

N 5

EC

N 6

MC

N 1

MC

N 2

MC

N 3

MC

N 4

MC

N 5

MC

N 6


Demo

GSS Long Version.exe


Resources

Article in ProSTEP magazine „ProduktDaten Journal“ No.1 / 2009

http://download.sap.com/SMIGlobal/download.epd?context=9CBB1995D46

8B47F1FEAAE118E7CE8412BD29F1A62FBE6F74BAAE929C5E099D2A

22CA7117E69F60C6808816552EF2657DB9373C204B477A2

SAP Rapid Deployment Solution (RDS) (http://www.sap.com/rds )

What is a RDS? Preconfigured software with fixed-scope

implementation services at a predictable price with the flexibility for future

extension. See also here: http://www.youtube.com/watch?v=O9rwL_yAghI

There is also a RDS for the transition from BOM to BOM:

SAP PLM rapid-deployment solution for synchronizing Bill of

Materials

http://download.sap.com/SMIGlobal/download.epd?context=9CBB1995D468B47F1FEAAE118E7CE8412BD29F1A62FBE6F74BAAE929C5E099D2A22CA7117E69F60C6808816552EF2657DB9373C204B477A2



http://www.sap.com/rds

http://www.youtube.com/watch?v=O9rwL_yAghI

http://www.youtube.com/watch?v=O9rwL_yAghI


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4 key take aways

More freedom and flexibility for engineering and manufacturing

due to separated structures and effectivitiesFlexibility

Traceability through links between eBOM and mBOM Transparency

Save time due to a system supported handover and

comparison of changes from eBOM to mBOMEfficiency

Integrated into existing SAP Application (BOM, Change

Management, etc.)Integration

Thanks you // Questions

?

Date post:	18-Jul-2016
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2904_Guided_Structure_Synchronization.pdf

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