Solution in Detail
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Manufacturing
ETO and Project Manufacturing
Executive Summary Solution Overview Contact Us
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Simplifying Complex Manufacturing
Manufacturers face challenges on many fronts
today: increased global competition, technical
issues in accommodating changing customer
requirements, government and industry
regulations, and the need for rapid response
to demand fluctuations. Together these require
an adaptable manufacturing process.
Companies are incorporating innovations such
as graphical bills of materials, mobile technol-
ogy, cybersecurity, and multiplatform, multi-
national IT support. But these innovations are
not always fully integrated, which means that
manufacturing processes are suboptimal.
This environment is complicated by the need
to comply with expanding government and
industry oversight.
Incorporating new technology to compete in the
evolving marketplace is critical. The engineer-
to-order (ETO) process supported by SAP
software allows for definition of each custom-
ers unique requirements, integrates innovative solutions, and minimizes expenditures of time
and money by reusing common products and
processes within the manufacturing lifecycle.
Manufacturers must monitor market dynamics
and employ innovation with a complete,
responsive, harmonized, and integrated
solution that efficiently manages process
and product cost and quality.
Efficient management of highly complex, variable, and tightly controlled
manufacturing is a challenge requiring technology that provides the necessary
process controls while quickly and accurately controlling product variation. Enabling Complex Builds
Managing Complex
Manufacturing
SAP Innovations
Improving Processes
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Accelerate the design-to-delivery cycle by
effectively managing complex designs. Com-
prehend faster using multimedia instructions.
Computer-aided process planning ties
multimedia work instructions with the bill of
materials (BOM) for various types of work such
as assembly, fabrication, rework, and tooling.
Visual manufacturing graphics tie the BOM to
work instructions. BOM management provides
engineers with tools to create multilevel product
structures with closed-loop BOM validation
from design through delivery.
Project manufacturing keeps track of the
complex processes required to engineer,
manufacture, and deliver complex configurable
products.
Efficient manufacturing execution, in
conjunction with scheduling and shop-floor
process controls, quality management, and
as-built records, provides for efficient and
high-quality production.
Production deviations can be recorded
and tracked for closed-loop disposition
and corrective action.
Integrated Answer for Complex Builds
Get the intuitive solution needed to build complex, highly regulated products.
Manage configuration information and processes, including changes. Integrate
graphic design into the build to simplify comprehension. Manufacture deliverables
and components, enforcing regulatory and customer-driven requirements.
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Enabling Complex Builds
Managing Complex
Manufacturing
SAP Innovations
Improving Processes
39% Lower manufacturing cycle
time where quality system has
simplified data sharing and
integration of inspection
planning with related
applications
Source: SAP Performance
Benchmarking
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For manufacturers, efficiency and intuitiveness of processes can make the
difference between success and failure. Best-run manufacturers optimize
profitability and resource expenditure by efficiently managing production definition
and change. This allows them to provide their products at minimum cost. SAP
facilitates this outcome with its integrated planning and execution solutions,
resulting in:
Proficient Manufacturing Control
Reduced change incorporation cycle time
Accelerated design-to-delivery cycle
Improved manufacturing profitability
Improved accuracy of finished products
Reduced quality and compliance costs
47% Lower manufacturing cycle
time for organizations in
EMEA where control of
processes is through pull-
based production schedules
Source: SAP Performance
Benchmarking
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Enabling Complex Builds
Managing Complex
Manufacturing
SAP Innovations
Improving Processes
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Manufacturing innovations are providing new
ways to reduce costs throughout the business:
Analytics solutions help optimize all areas of
manufacturing from start to finish organizing and managing business processes and costs.
Mobile solutions provide report and shop order
data wherever the Internet is available on a
choice of devices. Manufacturers can accomp-
lish more with less, tailoring access to tasks
at hand while improving quality and profitability
in the face of increased complexity and
competition.
Cloud solutions can simplify implementation,
track remote assets, eliminate physical borders,
and manage cost and risk. They provide a
unified answer for manufacturing issues such
as vendor coordination and multiplant manufac-
turing, and enhance communication.
SAP software accelerates complex assembly
manufacturing by coupling product visualization
with mobile and cloud technology to boost
productivity throughout the product lifecycle.
Visualization using 3D graphical navigation and
search helps a companys diverse departments to center on the product. The resulting quality,
operational productivity, and time-to-market
improvements increase a companys competitive advantage.
SAP Innovations
SAP assists in bringing technology innovations to the manufacturing supply chain.
These innovations accelerate comprehension, simplify and expand communication,
and enhance visibility to target activity, avoiding disruptions and speeding design-
to-market.
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Enabling Complex Builds
Managing Complex
Manufacturing
SAP Innovations
Improving Processes
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ETO Software Spans Manufacturing Needs
Process Planning and Scheduling
Define and organize tasks and resources globally to adapt to changing customer
and production needs.
Visual Manufacturing
Use leading 3D visualization technology to unify and accelerate the design-to-
manufacturing process.
Project Manufacturing
Track engineering, manufacturing, assembly, shipping, and installation processes
for an order.
Manufacturing Execution
Display, manage, and record highly engineered, changing data for production parts
and processes.
Process Planning, Scheduling
Solution Overview
Project Manufacturing
Visual Manufacturing
Manufacturing Execution
Why SAP?
ETO and Project
Manufacturing
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Engineer-to-order processes
leverage project, definition,
and execution functionality to
synchronize all aspects of a
products manufacturing cycle.
Managing Complex Manufacturing
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Process Planning, Scheduling
Solution Overview
Project Manufacturing
Visual Manufacturing
Manufacturing Execution
ETO and Project
Manufacturing
Process Planning,
Scheduling
Manufacturing
Execution
Project
Manufacturing
Visual
Manufacturing
Manufacturing
Business
Operations
Plant
Operations
Production
Operations Maintain
Orders
Resource
Planning
Define
Product
Manage
Released
Orders
Display Product
and Process
Structure
Maintain
Product
Structure
Define
Product
Life Cycle
Capacity
Leveling
Maintain
Resources and
Tools
Display and
Execute Orders
Define
Planning
Why SAP?
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Planning data is tied to BOM data that is
populated from the visual manufacturing tool
from SAP or another modeling tool. Changes to
product structure are managed to comply with
engineering requirements. The plan can include
tools, specifications, graphics, and standard
data, including data collection options, icons,
and uniform instructions for key processes.
Planning components are validated to help
ensure inclusion in planning as part of the
closed loop for components.
Planning updates to support production may
be performed prior to or during shop execution
but not afterward (except for data integrity
reasons).
Integrate BOMs with text, tools, and
graphics to create and maintain shop
work and tool maintenance instructions
for manufacturing, rework, and
maintenance.
Process Planning and Scheduling
Capabilities
Process Planning, Scheduling
Benefits
Technology Innovation
Solution Overview
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Conform with engineering requirements while
smoothly integrating parts and visual graphics,
specs, tools, and related documents.
Manage production resources for manufac-
turing, rework, and maintenance plans to
optimize the shop experience.
Create, standardize, and maintain work
instructions, specifications, and other
documents for an integrated, accurate, and
consistent manufacturing process. Manage
serialization, batch, time-sensitive material
(TSM), data entry, and first article inspection
(FAI) features.
Document, verify, inspect, and maintain critical
tools used in process planning to achieve
correct configuration, usage, and maintenance.
Manage the ability to view and edit planning
and production information for different
organizations within and outside the company.
Add and maintain inspection instructions to
assist in verifying compliance with internal,
customer, and government requirements.
Update work in process (WIP) where needed
due to engineering or manufacturing
requirements.
Document and Maintain Process Plans
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Capabilities
Process Planning, Scheduling
Benefits
Technology Innovation
Solution Overview
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Automate and coordinate parts and work
instruction incorporation, including visual
graphics and data storage.
Use standardized instructions to provide
consistent production and inspection text for
use throughout all facilities.
Record and manage processes and materials
with electronic buyoffs, serialization, batch,
data entry, TSM, and FAI features, simplifying
entry and recording of historical data for field
support.
Use data security by program and by field to
control collaboration by restricting the type of
data each organization can access, view, or
edit both inside and outside the company.
Integrate the management of tool usage and
maintenance. Provide visibility and control over
production with certifications.
Retrieve and maintain one or more production
orders simultaneously.
Reduce planning errors and product
lifecycle costs with consolidated,
standardized, intuitive, integrated
graphical planning and data storage
for simplified production processes.
Integrated Solution for Managing Complex, Changing
Products
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Capabilities
Process Planning, Scheduling
Benefits
Technology Innovation
Solution Overview
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Analytics solutions enable advanced modeling
and optimization throughout production, from
assessing resource utilization and improving
productivity to monitoring detailed stocking
information and measuring work-center
performance.
Innovations in Process Planning and Scheduling
Analytics solutions are now available
that can revolutionize manufacturing.
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Capabilities
Process Planning, Scheduling
Benefits
Technology Innovation
Solution Overview
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Manufacturers can use 3D visualization to
create, maintain, and communicate process
plans, BOMs, and work instructions. The 3D
visualization tools enable users to graphically
query and maintain multilevel product
structures while the system manages the
Visual Manufacturing
underlying data. The intuitive, graphical
presentation of complex structures enhances
understanding and promotes productivity in
structuring, integrating, manufacturing, and
servicing products across global manufacturing
systems.
Solution Overview
Use intuitive 3D visualization to create,
maintain, and communicate process
plans, bills of material, and work
instructions. Graphically query and
maintain multilevel product structures.
Capabilities
Visual Manufacturing
Benefits
Technology Innovation
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Improve efficiency with visual manufacturing.
Use instance-aware product structures to
develop and coordinate BOM structures,
process plans, and work instructions.
Integrate visual manufacturing with enterprise
resource planning (ERP), product lifecycle
management, and manufacturing executions
systems.
Integrate visual/spatial and analytical data from
various sources with production instances of
components.
Graphically query, filter, and maintain multilevel
product structures while the system manages the underlying data.
Manage extremely large, complex structures
with massive designs and data sets.
Minimize impact on computing resources.
Enable Efficient Manufacturing
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Solution Overview
Capabilities
Visual Manufacturing
Benefits
Technology Innovation
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Product structure integration from design
completion through manufacturing and shipping
eliminates duplication of design elements. This
provides a smooth handover from definition to
execution.
Graphical tools greatly simplify the query and
maintenance of process and product data
required to support the complicated structures
associated with complex manufactured prod-
ucts. At the same time, they improve product
and process quality.
Integration with tools from SAP, such as for
business and production planning, minimizes
data entry and greatly reduces input time and
errors.
Accelerate Comprehension and Consolidate Product
Knowledge
The SAP 3D Visual Enterprise Viewer
application accelerates work instruction
comprehension and minimizes the need for
written instructions. This is especially valuable
in high-turnover, multilanguage shops.
The end result of all these benefits is to reduce
manufacturing costs and lead times and deliver
products to the customer faster, all the while
supporting compliance with quality and safety
standards.
Simply and quickly access and maintain
multilevel product structures in an
intuitive graphical manner. Enhance
understanding and eliminate unneces-
sary duplication of effort for complex
structures.
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Solution Overview
Capabilities
Visual Manufacturing
Benefits
Technology Innovation
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Graphics from multiple software platforms can
be rendered using the solution for visual
manufacturing from SAP. The graphics can
then be displayed on several device platforms
based on the manufacturers needs.
Innovations for Visual Manufacturing
Metadata associated with the graphics can be
displayed using the solution and can be queried
using business analytics tools.
Production is simplified through use of
mobile platforms that allow devices to
display instructions and provide
analytics.
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Solution Overview
Capabilities
Visual Manufacturing
Benefits
Technology Innovation
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Use project manufacturing functionality to
manage long production cycles from product
definition through shipping, including quotation
and production phases.
Use work breakdown structures (WBS) to
define project tasks, materials, resources, and
capacities for logistical planning and execution.
Project Manufacturing
Take advantage of advanced project and prod-
uct scheduling, constraint-based production
schedules, and interactive simulation for what-if
scenarios.
Identify impact of added or changed production
orders. Use advanced planning and scheduling
to improve delivery rates, reduce inventories,
and react better to production changes.
Solution Overview
Structure a project from initial customer
quotation through production project
scheduling. Manage work breakdown,
scheduling strategies, and project
capacities.
Capabilities
Project Manufacturing
Benefits
Technology Innovation
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Project manufacturing tracks engineering,
manufacturing, assembly, installation, and
shipping, keeping track of order-related
activities.
Rough-cut planning provides initial basic dates
and key resources for project orders. BOMs,
routings, and drawings are not required and
may be preliminary. Rough-cut planning is kept
separate from production capacity analysis but
can be integrated when firm.
Prototype development is supported, including
multiple integrated manufacturing activities.
WBS functionality is available to structure
the overall project. Task and relationship
networks, including material and capacity requirements, trigger logistical planning and
execution.
Changes to project and WBS structures are
supported over a projects lifetime.
Manage Complex Product Build Cycles
Templates are available to accelerate
structuring for both work breakdown and
networks.
Various methods of analysis and scheduling
strategies are supported, including back-
ward/forward, finite/infinite resources, and
dates in the past allowed/forbidden.
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Solution Overview
Capabilities
Project Manufacturing
Benefits
Technology Innovation
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Project scheduling functionality simplifies and
integrates scheduling using interactive, intuitive
tools. This provides users with current, accu-
rate visibility into project and product sched-
uling, identifying constraints early in the
development lifecycle, improving production
and request for quotation/request for proposal
processes.
Multiple scheduling strategies are available to
remove backlog and improve planning results.
Key performance indicators (KPIs) are moni-
tored, including lead time and delay.
Efficient Planning Improves Complex Manufacturing
Activity
Resource allocation is enhanced with inter-
active simulation of a variety of scenarios to
minimize backlog and delays, improving
capacity utilization.
Simulation also provides greater transparency
and alerts for early detection of bottlenecks and
missing components.
Leverage the advanced planning and
scheduling functionality for project
manufacturing to manage and stream-
line overall activities related to complex
custom sales orders.
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Solution Overview
Capabilities
Project Manufacturing
Benefits
Technology Innovation
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Analytics and graphics solutions enable
advanced modeling and optimization through-
out every aspect of the manufacturing network,
from assessing current downstream demand to
improving new product launches.
SAP innovations improve complex
assembly performance across the
enterprise.
Innovations for Project Manufacturing
Mobile solutions give manufacturers always-on
access to production status reporting and
exceptions and alerts, providing for simpler
processes, better decision making, and fewer
risks to customer service.
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Solution Overview
Capabilities
Project Manufacturing
Benefits
Technology Innovation
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Organize and control production and other
order types by work area, worker, priority, and
operation.
Display context-sensitive 3D visualization, work
documents, tools, text, specs, drawings, and
external links in a simple, intuitive way.
Manage simple or complex buy-off confirmation
processes and callboards.
Manufacturing Execution
Solution Overview
Manufacturing execution for complex
assembly efficiently manages shop-floor
product and processes, scheduling
priorities, quality management, and
as-built records.
Capabilities
Manufacturing Execution
Benefits
Technology Innovation
Integrate standard processes, data entry,
complex data entry, and warning icons.
Support part and process nonconformance
management integrated with order and
operation completion.
Bundle all recorded product data associated
with an order. Store it with production BOMs to
create a complete as-built record.
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WIP documentation, including production and
rework orders, manages each workers access rights to actions such as start, stop, complete
work, hold/release, split, reschedule, close,
reopen, certification, batch activity, callboards,
and more.
Work queues and assignments let work be
assigned to personal queues or grouped for
work by tasks or operations.
Visual work instructions (2D and 3D) can be
linked to parts lists and used to display
assembly or disassembly activities. Tools,
specifications, work instructions, and more are
displayed.
Data collection and serialization are integrated,
stored, and archived with work instructions.
Contract tool manufacturing and maintenance
activity and listing in shop orders are available.
Manage and Document Shop Activity
Performing first articles, managing time-
sensitive material, and tracking orders through
production are supported.
Nonconformance management controls shop
quality.
As-built BOMs graphically display the structure
of components and assemblies as they are
completed.
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Solution Overview
Capabilities
Manufacturing Execution
Benefits
Technology Innovation
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Management of activity by predefined worker
privileges and certifications to match defined
production order tasks simplifies the manage-
ment of work in production.
The automated display of WIP by order or
operation within natural groupings simplifies
management of workers and shop orders.
Visual work instructions (2D, 3D) accelerate grasp
of instructions and minimize issues with compre-
hension of the written word. This is extremely
useful in high-turnover, multilanguage shops.
Integrated Solution Manages Complex, Changing WIP
Reduce cycle times and order proces-
sing costs with efficient execution
features. Minimize rework and repairs.
Reduce inventory. Assimilate users
quickly through intuitive interfaces.
Visual links between work instructions and
product data (serialization, time-sensitive,
tooling, and other information) simplify
collection of that data. Because visualization
is so natural, it reduces collection errors and
streamlines the shop experience.
Integration of first article (part) inspection
simplifies production instructions. Simplified
management of time-sensitive materials
reduces excess and expired materials.
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Solution Overview
Capabilities
Manufacturing Execution
Benefits
Technology Innovation
23 / 27 2013 SAP AG or an SAP affiliate company.
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Analytics solutions enable advanced modeling
and optimization throughout production, from
assessing resource utilization and improving
productivity to monitoring detailed stocking
information and measuring work-center
performance.
.
Innovations in Manufacturing Execution
Analytics solutions can now be
combined with mobile solutions to
revolutionize manufacturing.
Mobile solutions give users access to
production instructions wherever they are
needed. They reduce throughput time by
providing access when and where it is needed
Executive Summary Solution Overview Contact Us
Solution Overview
Capabilities
Manufacturing Execution
Benefits
Technology Innovation
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Engineer-to-Order and Project Manufacturing Value Map
Executive Summary Solution Overview Contact Us
Process Planning, Scheduling
Solution Overview
Project Manufacturing
Visual Manufacturing
Manufacturing Execution
ETO and Project
Manufacturing
Production
Planning and
Scheduling
Quality Planning
and Control
Manufacturing
Execution
Production
Planning and
Scheduling
Performance
Visibility and
Monitoring
Quality Planning
and Control
Manufacturing
Execution
Process Planning
and Scheduling
Manufacturing
Execution
Visual
Manufacturing
Engineering
Project
Manufacturing
Production
Planning and
Scheduling
Manufacturing
Execution
Lean Six Sigma
Analysis
Poka Yoke
Processing
Collaborative
Manufacturing
External
Processing
Subcontracting
Core
Corporate Quality Quality Planning
and Control
Quality
Operations
Make-to-Order
Manufacturing
Outsourced
Manufacturing
Repetitive
Manufacturing
Engineer-to-Order
and Project
Manufacturing
Lean
Manufacturing
Quality
Management and
Compliance
Performance
Visibility and
Monitoring
Why SAP?
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Why SAP?
Manufacturing and business solutions from SAP help companies closely align
operations with corporate objectives and integrate manufacturing with business
processes, to achieve greater marketplace success and optimize IT investments.
Production planning, scheduling, execution, and quality assurance are all integrated in solutions for
complex assembly manufacturing from SAP.
These solutions include a comprehensive portfolio of closed-loop processes across planning,
scheduling, and execution that leverage industry best practices.
Organizing and enabling asset utilization while simplifying and expediting manufacturing processes
across the value chain, these solutions serve the complete value chain for complex assembly.
SAP software helps customers harmonize their existing landscape and rapidly leverage industry
best practices.
SAP technologies such as mobile computing with analytics help enhance the user experience with
touch user interfaces and role-specific mobile apps.
Executive Summary Solution Overview Contact Us
Process Planning, Scheduling
Solution Overview
Project Manufacturing
Visual Manufacturing
Manufacturing Execution
ETO and Project
Manufacturing
Why SAP?
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Benchmark Your Performance
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benchmarking program from SAP available free to SAP customers and select prospects. The SAP benchmarking program has helped more than 3,000 organizations assess their
strengths, uncover areas for improvement, and identify best practices and IT strategies that
generate clear, tangible value not someday, but today.
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Solution in Detail
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Manufacturing
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Specific manufacturing operations:
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2013 SAP AG or an SAP affiliate company. All rights reserved.
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