© SAP 2007 / Page 2
ERP
SFAC
Paradigm Change in the Definition of theManufacturing Landscape
MOM
SFAC
MES
SFAC
ERP
Separated Systems Principles
Plant MaintenanceEquipment QualificationMaintenance OrdersTime TicketsComponent -ConsumptionWork AssignmentTools
Plant MaintenanceEquipment QualificationMaintenance OrdersTime TicketsComponent -ConsumptionWork AssignmentTools
Production PlanningProduction Orders /Process Orders (S88)Operations / PhasesTime TicketsMaterial ConsumptionsPI Sheet / ElectronicWork Instructions
Production PlanningProduction Orders /Process Orders (S88)Operations / PhasesTime TicketsMaterial ConsumptionsPI Sheet / ElectronicWork Instructions
Warehouse Mgmt.Production SupplyTransportation Orders
Warehouse Mgmt.Production SupplyTransportation Orders
© SAP 2007 / Page 3
Quality Mgmt.Inspection TasksInspection LotsSample ManagementUsage DecisionTest Results -Recording
Quality Mgmt.Inspection TasksInspection LotsSample ManagementUsage DecisionTest Results -Recording
SAP ERP Touchpoint Processes withManufacturing
ERP
ERP
WMWMWMWM PMPMPMPM QMQMQMQM PP /PP /PPPP--PIPIPP /PP /
PPPP--PIPIAPOAPO
PP/DSPP/DSAPOAPO
PP/DSPP/DS
Human ResourcesQualification Records
Human ResourcesQualification Records
Materials Mgmt.Inventory ControlGoods MovementBatch InformationMaterial -ReservationsMaterial -CharacteristicsPurchasingTools
Materials Mgmt.Inventory ControlGoods MovementBatch InformationMaterial -ReservationsMaterial -CharacteristicsPurchasingTools
MMMMMMMMFIFI COCO HRHRHRHR
© SAP 2007 / Page 4
Manufacturing Levels and LandscapeUsing ERP Manufacturing only
FIFI COCO
ERP
/ SC
MER
P / S
CM
SFAC
SFAC
HRHRHRHR WMWMWMWM MMMMMMMM PMPMPMPM QMQMQMQM APOAPOPP/DSPP/DSAPOAPO
PP/DSPP/DS
DCS / PCSDCS / PCS
~1s
OPC
SAP ODA
DevicesDevices
PIPI--PCSPCS
Industrial Bus
PI Sheet /Electronic
Work Instructions
PP /PP /PPPP--PIPIPP /PP /
PPPP--PIPI
Aut
om. P
roce
ssM
essa
ges
…Weigh ScalesActors Meters
Synchronous Data Transfer Asynchronous Data Transfer
ProcessProcessMessagesMessages
ControlControlRecipesRecipes
FunctionFunctionCallCall
MO
MM
OM
~8h
SeparateManufacturingSystems(MES, LIMS, Maintenance)Visiprise / SAP ME,Werum, … )
SeparateManufacturingSystems(MES, LIMS, Maintenance)Visiprise / SAP ME,Werum, … )
Data HistorianData HistorianSCADA / HMISCADA / HMI
MII
© SAP 2007 / Page 5
Manufacturing Levels and LandscapePP / PP-PI
FIFI COCOERP
/ SC
MER
P / S
CM
SFAC
SFAC
HRHRHRHR WMWMWMWM MMMMMMMM PMPMPMPM QMQMQMQM APOAPOPP/DSPP/DSAPOAPO
PP/DSPP/DS
DCS / PCSDCS / PCS
OPC
SAP ODA
DevicesDevices
PIPI--PCSPCS
Industrial Bus
PI Sheet /Electronic
Work Instructions
PP /PP /PPPP--PIPIPP /PP /PPPP--PIPI
Aut
om. P
roce
ssM
essa
ges
…Weigh ScalesActors MetersSynchronous Data Transfer Asynchronous Data Transfer
ProcessProcessMessagesMessages
ControlControlRecipesRecipes
FunctionFunctionCallCall
MO
MM
OM Third Party
Systems(MES, LIMS, Maintenance)Visiprise, Werum, …
Third PartySystems(MES, LIMS, Maintenance)Visiprise, Werum, …
Data HistorianData HistorianSCADA / HMISCADA / HMI
Transaction DataMaster Data
XStepRepository
Routing / Recipe Production / Process Order
BOMXSteps
Header
Operations/ Phases
BOMXSteps
Header
Operations/ Phases
StandardXSteps
PP /PP /PPPP--PIPIPP /PP /PPPP--PIPI
© SAP 2007 / Page 6
PP / PP-PI:XSteps, Master and Transaction Data
Transaction DataMaster DataOrder
Work Centers/ Resources
Materials(MM)
XStepRepository
Routing / Recipe
+
+
+
BOMXSteps
Header
Operations/ Phases
+
++
+
+
BOMXSteps
Header
Operations/ Phases
+
+
+
+
+
Control Recipes
Electronic Work Instructions / PI Sheets
Documents(Cross)
Equipments(PM)
P P
Header with order information
Containers for Operations / Phases(can be collapsed)
Instruction containers for convenientstructuring
Long text elements are on the left side
Short text and input elements are on the rightside
Tables stretch over the whole widthRepeated data input (extendable with new lines)Grouped elements with similar structure(e.g. check lists, generated material lists, …)
Scrollable
Input history can be logged
Comments can be entered at any time
© SAP 2007 / Page 7
Features of the PI Sheet / Electronic WorkInstruction (I)
PI Sheet - ChangeProcess order: 000123456 Material Number 10001234 >>Change -> Display Save Complete Print Create Comment
Phase 0010
Goods receipt
Weighing
Preparation:• Enter production date• Enter tare weight of pallet• Enter average weight of pieces
Weighing• Put bin on the weigh scale• Get bin weight• Check result and confirm (OK?)
Sign the goods receipt
Production Date 08.06.2006
Tare weight of bins [kg] 1.000
Avg. piece weight [mg] 200.0
Signature
Total of pieces 21000
Output of text instructions
In- and output of valuesDefault values, value validation
Tables
Calculations
Function calls
OPC data access(e.g. read measurement from device)
Digital signature (simple, multiple)
Automatic generation of order-related object(e.g. documents, components,…)
Event-triggered execution of commands and functionsAutomatic execution of functions (e.g. immediate check of material status)Activation/deactivation of instructions based on conditions
Process messages(Activity reporting, material consumption/production,…)
© SAP 2007 / Page 8
Features of the PI Sheet / Electronic WorkInstruction (II)
Tablet weighing
XStep Life Cycle (I)SXS Repository Routing/Recipe Order
© SAP 2007 / Page 9
SXS Repository
XStep Section of Routing
XStep Section of Production Order
SXS with parameters
Generated elements(3 material componentsassigned to the order)
Parameter values related to a specific component
Automatic valuationof parameters
Routing-specific parameter values
XStep Section of Production Order
Electronic Work Instruction (EWI)
XStep Life Cycle (II):Order EWI/PI Sheet Process Message
© SAP 2007 / Page 10
Parameter values (Diameter Setup)
Line completed
PP_CONS Process Message
Material List in Production Order
Default value Deviation
Process messagebooks materialconsumption
© SAP 2007 / Page 11
Execution Steps – Summary
XSteps are easy to create and maintain. Much of the day-to-day work can bedone by functional departments. The IT department can concentrate on morecomplex areas.
The repeated use of standard building blocks (SXS) reduces the maintenanceeffort for the master data definition
‚One-stop shop‘ for the worker to access and provide all ERP-relatedinformation. No need to run multiple transactions.
Flexibility and speed by dynamic and event-triggered instructions
Control of the material and information flow between ERP and productionsystems (OPC)
Information and XStep examples are available on:BPX Community for Manufacturing