Rockwell Automation and SAP Journey of...

Copyright © 2012 Rockwell Automation, Inc. All rights reserved.

Jeff MoranskiBusiness Stream LeadProduct Lifecycle Management

Barry JerebManager, Product Selection ToolsGlobal Sales and Marketing

Rockwell Automation and SAP

Journey of Discovery

Topics

• Overview of Rockwell Automation

• Implementation approach (team structure, project timeline, etc.)

• Configurable product line scope – KMAT development

• Configurable system line scope – KMAT development

• Opportunities to Succeed – Making the Right Choices

• Lessons learned


Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 3

Rockwell Automation At A Glance

• Fiscal 2011 Sales:Approximately $6.0 billion

• Employees: About 21,000

• Serving customers in80+ countries-- emerging markets over22% of total sales

• World Headquarters: Milwaukee, Wisconsin, USA

• Trading Symbol: ROK

33

Leading global provider of

industrial power, control

and information solutions


Serving You Around the World

North America:

300 sales & support locations

9,400+ employees

Latin America:

30 sales & support locations

4,000+ employees

Europe, Middle East & Africa:

90+ sales & support locations

50+ countries

4,000+ employees

Asia Pacific:

60+ sales & support locations

20+ countries

3,600+ employees


Optimizing Plant Performance, Protecting Your Investment

• Electronic overload protection relays– Increase access to information,

enhance protection & speed troubleshooting

• Soft starters– Decrease mechanical wear

& increase control functionality

• Variable speed drives

– Reduce energy consumption, improve performance & preserve equipment

• Packaged & pre-engineered solutions

– Increase productivity & decrease risk

• Turnkey motor control solutions

– Access manufacturing, engineering & commissioning expertise anywhere

Control | Communicate | Protect


Delivering Exceptional Valueto Your Application

• Power

– Circuit breakers, disconnect switches, contactors & starters…

• Connectivity

– Terminal blocks, wiring systems, distributed I/O, DeviceNet media…

• Logic

– Relays, timers, temperature controllers, small controllers…

• Sensing & Switching

– Photoelectric sensors, limit switches & proximity sensors…

• Operator Interface

– Push buttons, signals & alarms, electronic operator interfaces…

• Safety

– Safety contactors & control relays, interlock switches…

Quality components increase functionality & last longer – saving you time & money


Increase flexibility & responsiveness while reducing costs & improving quality.

• Bridgestone • Daimler• Chrysler• Ford• GM• Goodyear• Hyundai • JCI • Lear • Magna• Michelin• Toyota

Increase flexibility & responsiveness while reducing costs & improving quality.

• Bridgestone • Daimler• Chrysler• Ford• GM• Goodyear• Hyundai • JCI • Lear • Magna• Michelin• Toyota

Automotive

Satisfy consumer demand, while reducing costs, minimizing waste & improving asset performance.

• Anheuser-Busch InBev• Coca-Cola• Kellogg• Kraft Foods• M&M Mars• Nestlé• PepsiCo/Frito-Lay• SABMiller

Satisfy consumer demand, while reducing costs, minimizing waste & improving asset performance.

• Anheuser-Busch InBev• Coca-Cola• Kellogg• Kraft Foods• M&M Mars• Nestlé• PepsiCo/Frito-Lay• SABMiller

Food & Beverage

Reduce costs while meeting the demands of ever-changing regulations.

• Abbott Laboratories

• Eli Lilly

• GlaxoSmithKline

• Johnson & Johnson

• Merck

• Pfizer

• Roche

• Sanofi

Reduce costs while meeting the demands of ever-changing regulations.

• Abbott Laboratories

• Eli Lilly

• GlaxoSmithKline

• Johnson & Johnson

• Merck

• Pfizer

• Roche

• Sanofi

Meet regulatory challenges & improve quality, consistency, flexibility & time-to-market.

• 3M• Beiersdorf• Colgate-Palmolive• Henkel• Kimberly-Clark• L’Oréal• Procter & Gamble• Unilever

Meet regulatory challenges & improve quality, consistency, flexibility & time-to-market.

• 3M• Beiersdorf• Colgate-Palmolive• Henkel• Kimberly-Clark• L’Oréal• Procter & Gamble• Unilever

Consumer-Driven Industries Include…

Household & Personal Care Life Sciences

Consumer Packaged Goods


React to changing production conditions while maintaining operations at peak efficiency.

• BP• Chevron• ConocoPhillips• ExxonMobil• Shell

React to changing production conditions while maintaining operations at peak efficiency.

• BP• Chevron• ConocoPhillips• ExxonMobil• Shell

Oil & Gas

Execute real-time control & maintain critical process parameters to respond to customer demands.

• Alcoa• BHP Billiton• CEMEX • Holcim• Lafarge• Rio Tinto• US Gypsum• Vulcan

Execute real-time control & maintain critical process parameters to respond to customer demands.

• Alcoa• BHP Billiton• CEMEX • Holcim• Lafarge• Rio Tinto• US Gypsum• Vulcan

Mining / Metals / Cement

Increase yields while reducing risk & total cost of ownership by using a single automation control & information infrastructure.

• Agilent• Applied Materials• ATS Automation• Axcelis• IDC / CH2M• KLA-Tencor• Novellus• Praxair• Seagate

Increase yields while reducing risk & total cost of ownership by using a single automation control & information infrastructure.

• Agilent• Applied Materials• ATS Automation• Axcelis• IDC / CH2M• KLA-Tencor• Novellus• Praxair• Seagate

Heavy, Resource-Driven Industries Include…

Achieve low long-term cost &on-demand engineering expertise with scalable solutions.

• A & E Firms• Consultants• Design Engineer Firms• Design Institutes (Asia)• Global Municipalities• Privatizers (Europe)• Pump OEMs• System Integrators

Achieve low long-term cost &on-demand engineering expertise with scalable solutions.

• A & E Firms• Consultants• Design Engineer Firms• Design Institutes (Asia)• Global Municipalities• Privatizers (Europe)• Pump OEMs• System Integrators

Water / Wastewater Semiconductor / Electronics

Machine & Equipment Builders (OEMs)

• Preferred by leading OEMs in our focused segments including:

– Packaging: ADCO, Columbia Machine, Hartness, MaSipack, RA Jones, Schneider Packaging, Bradman Lake, Tetra Pak, Tissue Machinery Company, OPEM S.R.L., Krones, Bosch Packaging, Optima Group, Cavanna

– Converting/Print/Web: Black Clawson, Catbridge, Cerutti, CG Bretting, Curt G. Joa, Jennerjahn, Mark Andy, Nordson, PCMC, Fabio Perini, Fameccanica, Calemard/Spoolex, Futura

– Material Handling: FKI Logistex, HK Systems, Jervis B. Webb, Lantech, Selex Elsag, Grenzebach Maschinenbau, Takraf, Grundfos A/S, ECL, TGW, Knapp Logistik, Vanderlande, Harburg Freudenberg, VMI, Grenzebach, Karl Eugen Fischer

– Process: ABEC, A&B Process, AZO, GEA, Getinge, Glasstech, New Brunswick, Paul Mueller, Steris, Bühler, Aasted Mikrovaerk

– Assembly: ATS, ITCM, Mikron, Harburg Freudenberger, VMI Holland; Dürr, Comau, Grenzebach

– Alternative energy: Vestas

• Specified by leading end users in consumer and heavy, resource-driven industries around the world

Expertise to help you innovate, build better machines & lower your total cost to design, develop & deliver

10

Importance of Variant Configuration

Variant Configuration provides the foundation for enterprise core processes end-to-end• SAP Variant Configuration forms the functional foundation for processes that enable business strategies

• SAP VC must be used consistently in sales/marketing, order management, planning, manufacturing, engineering, customer service, and analytics

• SAP VC must support all product areas requiring customization: – Standard products (configure-to-stock)– Material variants (configure-to-order)– Configurable products (configure-to-order)– Non-standard products (engineer-to-order)– Systems/Solutions (configure-to-order/engineer-to-order)


• Support customer demand for highly configured product lines characterized by a high mix/low volume• Drive sales productivity and effectiveness• Increase growth and profit margins while decreasing costs, and time to market through intelligent customization• Customize marketing experience for product selection and configuration in order to differentiate our companies and our products and services effectively, and simplify complex selection• Treat configuration models and data as assets that can be leveraged inside/outside of SAP • Seek “open” configurator solutions that allow us to leverage our investment in model development by using the configurator in different marketing and sales scenarios on line and off line

Importance of Variant Configuration


Legacy Product Configuration Cycle

Drawings/Schematics

Bills of Material

DocsSpecs

ManufacturingRoutings

Price PackagedSolutions

Standard Components

Complex Systems

Resulting Data Build/ShipSelect/Book

• 24 legacy configurator tools using 4 core technologies with varying degrees of integration to multiple business systems.

• 1200+ product lines with configuration models

• Many man-year estimate for conversion to SAP models and user interfaceCopyright © 2012 Rockwell Automation, Inc. All rights reserved.

PLM Implementation Scope

Live Data Elements Total

Material Masters 750,000

BOMs 500,000

Documents 1.7 million

CAD Files 750,000

Routings 250,000

Product KMATs 500

System KMATs 72

Product Data Management

• Material Master (extensions, language, classifications, types, etc.)• Product Structure Management (BOM Management)• Eng Change Management (standard product, CTO, ETO, Systems)• Document Management• Product Design Integration: AutoCAD, Pro/E• Global Product marking master data• cFolders Collaboration (internal and external)• Order Engineering Integration

Configurator

• Variant Configurator (ECC)• Internet Pricing & Configurator (CRM - AP7)• Complex Order BOM and routing generation for CTO and ETO • System Configuration - PowerControl Builder and SAP Integration• Quotation & Proposal Management integration

Project Management

• Project Systems for Misc. Capital & Internal Projects w/ WBS• Project Systems for ETO - WBS & Networks w/ cross company code; Eng Labor reporting;

Goods issue processing w/ delivery from projects, Project progress, revenue recognition

Quality Management

• Inbound test/inspection; QIRs• Quality Notifications: (Manf/Supplier defects, Internal Block, MRB, In-Process

Test/Inspection (including ATE interface), Process Qualification, CAPA, OCN, Quality Certificates; Product Deviation Notification Outgoing Audit, Stop Order/Hold/Release/Waiver)

Idea to Offering

Product Continuation

Order Engineering

Idea Management

Consideration to Release (CPD)

Project & Portfolio, Management

Migration to Discontinuation

Locations/Users Total

US Plants 12

Sales Orgs 4

US Design Centers 6

Total users (Global Gen_all) 14,000

Primary Users (Engineers) 1,000+

Key Stakeholders: Business Units; Engineering Services


Implementation approach (e.g. team structure, project timeline, etc.)

• RA future state vision - including configurator vision

• Release strategy, timelines, and scope

• SAP upgrades and service packs

• Release cycle phase gates including release overlaps

• Methodology and tools

• SAP Client Environments and test cycles

– Client landscape

– KMAT and data deliverables and accuracy requirements for each cycle

– Synchronization of data

• Project management approach

– Master project plans (high level timeline) and stream level project plans

– Small group and team member task lists, etc.

• High level process overviews – Quote/Order to Cash for Products, systems/ CTO and ETO from CTO


Configurable Product Line scope –KMAT development

• KMAT types – True CTO versus Characteristic Search

• KMAT development phases

– Catalog number (SKU) validation

– Pricing

– BOM

– Routing

• KMAT management

– Complexity and work estimates

– Development and testing

– Rework and defect resolution: spec error, modeling error, source of truth error

• Conversion/development roles

– On-shore/Off-Shore IBM consultants

– Rockwell business team resources

– Rockwell IT resources

– Rockwell product owners

– Configurator Services

• Working with Offshore IBMCopyright © 2012 Rockwell Automation, Inc. All rights reserved.

Configurable Product Line scope –KMAT development

• Product Configuration– One KMAT per product line

– Product selection and resultant data for a single SKU, price, and production order

• Configuration purpose– Order to Cash configuration (aka Manufacturing configuration)

– Market to Quote configuration (aka Sales configuration)

• Phased KMAT implementation driven by release timelines

• RA scope: ~ 500 product lines = 500 KMATs

• Specification development for product KMATs: decentralized responsibility

• Specification workbook development (capture rules in Excel)– Manual spec creation

– Programmatic extraction from legacy systems

– Re-engineering the products to improve upon legacy vs extract and convert

– Rule simplification for table based development

• Qualification testing– Manual vs automated

– Comparison to legacy – good source of truth for comparison


Configurable System Line scope –KMAT and functionality development

• System configuration – Multiple KMATs per system

– Requires customer configuration at the unit KMAT level with system values

– Rule based validation and optimization of the structure/system

– System layout

• RA scope: 5 system lines utilizing approximately 200 system KMATs

• KMAT styles– Common KMATs

– Unit type KMATs

– Structure KMATs

• Additional KMAT development phases– Layout and optimization tool and rules (outside SAP)

– System level KMAT

– Engineered options

– Customer Specific options and tools

• All or nothing implementation for each release – all KMATs and tools are needed at cutover.

• Specification development for KMATs: centralized responsibility


Configurable System Line scope –KMAT and functionality development

• Order Engineering process (CTO & ETO from CTO)– Standardized manufacturing output for all plants

– Collective orders driven by a BOM/Routing structure and proxies

– Architecture - Quotation to Order Engineering output generation

• System configurator - outside SAP

• Configuration database - in ECC

• BOM/Routing structure and proxy material generator - in ECC

• Quote and quotation cost estimator - in CRM

• Engineering workstation /drawing & MES generator - outside SAP

• Qualification testing– Unit level testing

– System level testing of whole configured systems

– Engineered options

– Customer Specific options

– Real life order testingCopyright © 2012 Rockwell Automation, Inc. All rights reserved.


Opportunities to Succeed –

Making the right choices……

Configurator PerformanceModellingUser Interface DesignProcess Automation

Examples of Key Choices and Opportunities to Succeed

• Performance

– IPC/AP7 – Get Help

• Modelling

– Custom Ztables and Pfunctions for large BOM selection tables (>15k records) instead of variant tables to avoid time-intensive BOM explosion time and other development complexities

– Compliant Mode instead of Advanced Mode modeling for System Configuration

• User Interface Design (AP7/IPC)

– Develop custom UI based on standard instead of using standard

• Process Automation

– Automatically generate material variants for CTO products instead of leaving theKMAT material on the order

• System Configuration and Order Engineering Architecture

– Use IPC to do what it is good at instead of asking IPC to do everything

– Support order and manufacture of CTO system AND ETO from CTO system – had to have both – by embracing complexity

Let’s take a

closer look

at these


Configurator User Interface

Challenges:

• Non-intuitive standard interface for our users

• No support for entry and encoding or decoding of intelligent catalog numbers


21

Supporting Intelligent Catalog Numbers

20CC261M0AYNBNN0

• Organizational shorthand for communicating product information

• Long established method for commercial product identification

– Cost and inconvenience for customers and partners to change their drawings and documentation

– Cost to change marketing and product literature to refer to part numbers

“Why do you want to keep this?”


Component Configurator User Interface

Simplifed Customized User Interface – version 1

23

Catalog Number

Field for

Encoding and

Decoding

Catalog Number

Product attribute

selectionSAP standard

layout eventually

looked much like

our custom layout

Encoding and Decoding Supported by Java

Function Modules in CRM and ABAP Function

Modules in ECC


Version 2

• A material variant is an individual configuration of a configurable productmaterial that can be kept in stock

• The material variant’s material master is linked to the configurable material and configured using the characteristics of the configurable material.

• Variants can be manufactured in advance and supplied from stock when ordered (MV can be linked to BOM and routing of the KMAT)

Automatic Material Variant Creation Process

Standard Use of Material Variants in SAP

Rockwell Automation’s Use of Material Variants

• A material variant is created automatically AFTER a KMAT is used to order a variant We do it before too!



Having a material master for each configured product that is ordered helps facilitate the following processes:

• Product Returns which requires a material to return to stock

• Advanced planning and optimization

• Pricing/re-pricing and pricing history

• Faster customer service through better differentiation of line items

• Leverage other processes that use material master such as product labeling




New Configurations are Ordered with KMATs

Orders are replicated from ECC to CRM with the KMAT Configurable Material and Configuration

2727


The Hourly Job Picks Up All KMAT Order Items

and Creates Materials as Material Variants.



Data Used to Create the Material Variant

Catalog number of product ordered is compared with catalog number strings in table to identify a “template” material to use for material master

The material is created as a copy of the template with the data from the table laid over the top of the template.



The material classifications are created



The material is linked to the KMAT and extended to all the plants and storage locations, linked to the super BOMs and super Routings.


Automatic Variant Creation Process

Product Material Descriptions and Technical Descriptions are automatically generated and put into material master


Orders with KMATs are Switched to Material Variant Hourly

• The job checks whether newly configured material already exists by searching the catalog numbers and series designations of existing materials

• Substitutes the existing material if one exists or creates the new one if no match in found

• The KMAT is deleted and the material variant is inserted if there are no blocks on the material variant.


Opportunities to Succeed –

Making the right choices……

System Configuration andOrder Engineering

System Configuration and Order Engineering

Motor Control Centers



Where should KMATs be used?

Performance?Maintainability?Complexity?


36

MCC Super BOM with standard VC design

MCC

Shipping Block3Shipping Block2 Shipping Block16Shipping Block1x 16

Section8Section3Section2Section1x 8

Total Number of KMATs = 1x16x8x68

= 8704 Nested KMATs!

Unit1 Unit68Unit5Unit4Unit3Unit2x 68

Rules are complex, top-down, bottom-up and

sideways.



Solution: Custom App that punches out to IPC for configuring system components

Complex and performance intensive rules related to layouts and relationships between the individual KMATs placed in custom application

Used SAP for only what it was designed to handle effectively such as the Unit KMATs, Unit UI, BOMs, Routings, Costing.


System Configurator

Application

IPC JSP User Interface

IPC/AP7


SAP CRM

ECCMinimum Sized Compliant

Mode KMATs

• System Configuration User Interface

Component Selection

• Access to Component Configuration

• System Layout

• Automatic Slotting and Validation

• File/Project Management

• Quote Population

Configuration Data

Engineering and Manufacturing

Data Output Generation

Quote

and

Order


Architecture - Quotation to Order Engineering output generation

CRM Quote/Order

System Configurator

ECC order triggers

ECC configuration db

ECC configuration data

extraction/formatting

Engineering Workstation

ECCEngineering data

output

ECC order BOM/Routing

generation

CRMKBEs


Order BOM/Routing Format for System Products

Our complex order BOM/routing generationprocess leveraged the system KMATs in ECC in order to land the order BOM and routing output in a structure for use with collective production orders over a wide variety of scenarios

Using SAP’s collective order structure allows us to use standard SCM processes to drive just-in-time manufacturing of complex system products


Lessons learned

• Accelerate learning curve

– Have clear plan and goals for deliverablesof blueprinting and concept prototyping;know what you are trying to prove

– Send your people to training; don’t assume consultants will teach them

• Don’t ask configurator to do too much

• Intelligent Catalog Numbers are NOT Dumb

• Don’t lose differentiated processes and services in your SAP implementation

• Work to keep continuity of team (RA and partner)

• If you can envision it, you can do itCopyright © 2012 Rockwell Automation, Inc. All rights reserved.

Lessons learned

• Need diverse skills on your team– Requirements and technical scoping

– Project management

– Product knowledge

• specs

• testing

– Data analysis and conversion

– KMAT development

– End to End process knowledge and cross functional savvy

• supply chain (order to cash)

• commercial/customer facing (market to quote)

• Scope/ Risk management

• Project schedule alignment - implementation team, stakeholders, and product owners


Thank You!


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