Manufacturing Performance Management using SAP OEE (eBook)

Dipankar Saha works for IBM India as IT Architect & Service Delivery Lead for SAP Manufacturing. He has co-authored several books on SAP MII & ME and regularly participates in different public forums/events/seminars presenting papers on topics related to SAP Manufacturing. He has worked on several SAP MII, OEE & ME implementation projects globally defining solution architecture and managing solution deliveries. Previously he worked for SAP Labs India and was involved in the design and development of SAP MII. Dipankar is a SAP Certified Associate Enterprise Architect. He has around 14 years of experience in the IT industry and has a Bachelor's of Technology degree in chemical engineering.Mahalakshmi Syamsunder is a manufacturing solution consultant currently working for IBM India. She has contributed to solution consulting for various manufacturing and utility clients. She also carries a deep expertise in shop floor automation and was involved in design, development, training and implementation of projects on SAP MII, ME, OEE and plant automation. Mahalakshmi has a Bachelor's degree in electronics and communication engineering, and a Master's in technology management. She has 5 years of experience in automation and over 7 years of experience in SAP Manufacturing.Sumanta Chakraborty is an experienced professional with 18+ years of cross-industry experience in various roles. A mechanical engineering graduate from NIT - Durgapur, India, he started his career in automobile manufacturing and gradually moved into the development of enterprise software products around manufacturing, ERP and supply chain management. For the last 12+ years Sumanta has been with SAP Labs India Bangalore, and is currently in the role of SAP OEE Product Owner having end-to-end product management responsibility at the global level. He works with SAP customers and partners across the globe with a team spreading across continents. Sumanta is very well known in the SAP Manufacturing ecosystem.

Contents at a Glance 4
Contents 6
Foreword 12
About the Authors 14
Acknowledgments 16
Introduction 18
Chapter 1: Manufacturing Performance Management: An Overview 20
Need for KPIs to Optimize Manufacturing Performance 20
Benchmarking and Target Setting 22
OEE Standard and Its Calculations 23
The Need for an Effective Operator Interface for Data Collection 26
Shop-Floor to Top-Floor Integration 27
Summary 29
Chapter 2: SAP OEE: A New Product for Manufacturing Performance Management 30
SAP OEE on MII platform 30
Solution Architecture of SAP OEE 31
SAP OEE: Product Overview 34
SAP OEE Functional Model 34
SAP OEE Add-on Component in ECC 36
SAP OEEINT for Integration of ECC and OEE 38
SAP OEE Operator Dashboard (Worker UI) 38
SAP OEE Reporting and Analytics 40
SAP OEE: Benefits 41
Summary 41
Chapter 3: The SAP OEE Add-on Component of ERP 42
OEE Master Data in ERP 42
Shift Configurations 43
Configure Shift Grouping 44
Configure/Maintain Shift Definitions 45
Configure/Maintain Shift Sequence 45
Associate Shift with Work Center Capacity 46
OEE Configuration Data in ERP 48
Data Collection Category 49
Data Element Type 50
Data Element Type Configuration: Reported Element 51
Data Element Type Configuration: Calculation Element 52
Data Element 53
Data Element Configuration 53
Data Collection Contexts 54
Data Collection Contexts Configuration 55
Data Collection Element 55
Data Collection Elements Configuration 55
Hierarchy Node Classification 58
Hierarchy Node Classification Configuration 58
Machine Groups 58
Machine Groups Configuration 59
Production Modes 59
Production Modes Configuration 60
Production Activities 60
Configure Production Activities 61
KPI Configuration 61
KPI Configuration 62
Hierarchy Model in OEE 63
Global Hierarchy 64
Global Hierarchy Template Configurations 64
Defining Node Type 65
Global Hierarchy Configuration 69
Benefits of Global Hierarchy 72
Plant Hierarchy 72
Plant Hierarchy Template Configuration 72
Node Type as Plant 74
Node Type as Area 74
Node Type as Team 75
Node Type as Line 76
Node Type as Machine 77
Plant Hierarchy Configuration 78
Details Tab 79
KPI Targets tab 82
Classification Tab 83
Standard Rates Tab 83
Bottlenecks Tab 84
Machine Groups Tab 86
Technical Objects Tab 86
Node Delete 88
Reason Codes 88
Global Reason Codes 90
Plant Reason Code Configuration 93
Upload Plant Reason codes 94
ALE Customizing Settings in ERP for Integration with OEE 96
ALE Customizing Settings in ERP for Communication with MII 97
Define RFC destination 97
Logical System for ALE 101
Logical System Configuration 101
Partner Port 102
Partner Profile Configuration 103
Message Type 106
IDoc Type 106
Customer Distribution Model 107
Customer Distribution Model Configuration 107
Summary 109
Chapter 4: SAP OEEINT for Integration of ECC and OEE 110
Configuration Templates for OEEINT 112
SAP OEE NetWeaver Configuration CTC 113
SAP OEE Integration Configuration CTC 115
OEE Integration Configurations 120
Global Configurations 120
Supported Plants Configurations 121
IDoc Message Listener Configurations 122
Processing Rule Configurations 123
Scheduler Configurations 123
Workflow Configurations 125
Lifecycle Methods of Standard Workflow 126
Enhancing Standard OEEINT Workflow 127
Transfer of Data from ERP to OEE 128
Transfer of Master Data and Transfer of Material/Work Centers 129
Transfer of OEE Master Data and Transfer of Plant Hierarchy/Reason Codes 130
Transfer of OEE Configuration data 131
Queue Monitor 134
Summary 135
Chapter 5: OEE Configurations in SAP MII 136
User Roles and Authorizations 136
User Roles for SAP ERP 136
User Roles for OEE Integration Services in SAP MII 137
SAP OEE CTC Wizards 138
SAP OEE Configuration CTC 139
SAP OEE Migration CTC 141
SAP MII Configurations for SAP OEE 144
Display ERP System Data 146
General Configuration 148
Dashboard Assignment to User Group 148
User Administration in SAP OEE 148
Dashboard Assignment in OEE 149
Customization Configuration 151
Reason Code Configuration 152
Extension Configuration 154
Activity Configuration 156
Activity Configuration Options 157
Example to Create an Activity 158
Standard OEE activities 160
Order Status Description Configuration 160
Order Dispatch 160
Scheduled Downtime Maintenance 161
Create Scheduled Downtime 162
View Existing Scheduled Downtimes 162
OEE Configurations Transport 162
Summary 163
Chapter 6: SAP OEE Dashboard 164
Dashboard Configuration 164
Dashboard Configuration Elements 164
OEE Dashboard Description Tab 165
Dashboard Section Content 165
Dashboard Buttons 165
Dashboard Button Options 166
Types of OEE Dashboard 166
Plant Monitor Dashboard 166
Line Monitor Dashboard 167
Operator Dashboard 168
Dashboard Selection 170
Line or Work Unit Selection 170
Shift Selection 171
Current Shift Order 171
Current Shift KPIs 172
Line Availability Summary 172
Top Downtimes 173
Dashboard buttons: Manage Orders 174
Dashboard buttons: Manage Downtimes 179
Minor Stoppages 180
Machine Breakdowns 182
Line Down 183
Shared Downtimes 184
Create Shared Downtimes 185
Flow Time 185
Dashboard buttons: Report Production 186
Dashboard buttons: Report Speed Loss 186
Dashboard buttons: Report Standard value parameter 187
Dashboard buttons: Review Order 188
Dashboard buttons: Review Shift 188
Standard Functionalities of SAP OEE 189
Download and Release of Order-Operation 190
Execution of Order-Operation, Which Includes Start, Hold, and Complete an Order 190
Order Downtime Tagging 192
Four KPI Calculations in Real-time 192
OEE KPI Calculation 193
Goods Movement in OEE 195
Goods Receipt 196
Goods Issue 196
Backflush of Components 196
Manual Goods Issue Trigger from OEE 197
Update Order Confirmation and Goods Movement to SAP ERP 198
Real-time Monitoring of Shop Floor through OEE Dashboard 199
Near Real-time Replication of OEE Transaction Data to HANA 200
Summary 202
Chapter 7: SAP OEE Customizations 203
OEE Custom Actions 203
Custom Actions for OEE Shop-Floor Data Collection 204
OEE Data Model 207
Data Model Flow for Events 208
Data Flow for Order Run 209
Customizing OEE Configuration Data 210
Customizing Production Activity 210
Customization of OEEINT Workflow Configurations 215
Customization Scenarios of OEE Extensions 216
Access Global Context from Standard SAP OEE Dashboard 217
Prerequisites 217
SAP MII–Based OEE Analytics 218
Customization Scenarios in SAP OEE 218
Scenario 1: Manufacturing Automation Systems’ Integration with SAP PCo and SAP MII 218
Prerequisites 219
Scenario 2: Shop-Floor Data Buffering in SAP MII 222
Scenario 3: Custom Extensions in SAP OEE Dashboard 224
Develop BLS Transaction for Custom Extension 224
Create a Custom Activity 225
Configure Custom Extension 225
Scenario 4: Custom SAP OEE Dashboard 226
Scenario 5: Calculate and Monitor Custom KPI 229
Prerequisites 229
Scenario 6: QM Notification Handling 233
Industry Use Cases for SAP OEE 236
Summary 243
Chapter 8: Additional features of SAP OEE Management 244
Creating PM Notification from Worker UI 244
Prerequisites 245
Customization Configurations 245
Activity Configurations 245
Report Notification in Manage Downtime 246
Create PM Notification 247
Line-Specific Alerts 249
Data Collection at Machine Level 250
Manual Correction of Order Execution Data 251
Visual Icons and Customer Logo in the Dashboard 252
Data Maintenance through CSV/XML Upload 254
Data Maintenance of Reason Codes through CSV Upload 254
Upload of Reason Code to OEE 255
Data Maintenance of Downtimes through CSV Upload 255
Upload of Downtimes in OEE 256
Upload of Reason Code in OEE Add-on 256
Quick Setup of a Demo SAP OEE Plant without Having an ERP Connection 257
SAP OEE Demo Plant Master Data Setup CTC 257
SAP OEE Demo Plant Order Data Setup CTC 259
Download and Reuse the Standard UI Code for Customization 259
Application Launch Pad for Goods Movement 260
Configurations Required to Use the Goods Movement App Customization Configuration 261
Activity Configuration 261
Activity Options to Configure the Goods Issue App 262
Activity Options to Configure the Goods Receipt App 263
Dashboard Configuration 265
Configure the Application Launch Pad 265
Goods Movement Process 265
Goods Issue 265
Goods Receipt 268
Use Case for Goods Movement 270
Summary 270
Chapter 9: SAP OEE: Reporting and Analytics 271
Real-Time Dashboards: Worker UI (Dashboard) and Plant Monitor 272
Local Plant-Level Reporting 274
Global Consolidated Reporting at the Corporate Level with SAP HANA 279
Summary 290
Appendix 291
Section 1: Automated Data Collection 291
SAP OEE Service Interface: SAP OEE Integration 292
Section 3: Customization Configuration In General Configurations 316
Section 4: Standard Activity Configuration 321
Section 5: Extension Configuration 328
Section 6: Global Context 342
Sample XML View Code 345
Glossary 347
Index 350