Professional Documents
Culture Documents
October 2006
What is a Perfect Plant?
Capability Examples
Customer Success
Contents
OEE
Asset Utilization
Asset Reliability
Yield
Not one measure can show
Schedule Compliance a complete view operations
Assay/Quality Index
Production Volumes/Throughput
Fill Rate
Example- OEE
OEE measures
Capability Examples
Customer Success
Achieving the Perfect Plant with Asset Utilization, Planning and
Manufacturing Execution all Aligned- The hill climb challenge
Monthly
Monthly Before the Event
Operations Responsive
Responsive
Planning
Planning
Planning Manufacturing
Manufacturing
Reactive
Reactive During the Event
Manufacturing
Manufacturing
Manufacturing
Execution After the Event
Unplanned
Events
Preventative
Preventative Manufacturing
Maintenance
Maintenance Automated
Automated
Execution
Monitoring
Monitoring
Linked with Asset
Management Before Event impacts
Proactive
Proactive production
Monitoring
Monitoring and tightly coupled with
Asset Performance and EAM
Issues alerted
Responsive
Responsive Before the Event
Monitoring
Monitoring has a major impact
Reactive
Reactive Issues Captured
Manufacturing Monitoring
Monitoring During the Event
Execution
Unplanned Issues reported
Events after the Event
Occurred
DISCONNECT
What’s happening during every shift?
Asset Performance and Reliability Trends
EAM/ ? Capacity availability and utilization
Product Genealogy tracking and QM
Operations Process Variability
DISCONNECT
DISCONNECT
What’s happening at each line?
Predictive Maintenance requirements
? Machine Breakdowns / Unplanned Downtime
Plant Level Operating Efficiencies
Quality Index
SFAC - Plant Floor Automation and Control Systems
EAM-Enterprise Asset Management
DCS – Distributed Control Systems
© SAP Labs 2006, Draft – Confidential / 19
Addressing these needs requires integrating the real-time Plant Floor with
the Enterprise and poses serious challenges….
Enterprise
Disparate Plant System Landscape
A Typical plant will have between 10 and 50 Plant
floor systems
DISCONNECT
A multi-site producers will have between 40 and
700 Plant systems across its enterprise Factory
Capability Examples
Customer Success
Enterprise Asset Management Landscape and value to produce
the Perfect Plant- Just one example
Together, EAM and Production Aggregation of information for execution of common EAM
Data provide a comprehensive transactions from a single point.
solution that includes asset Providing views of key information such as BOMS, maintenance
connectivity, performance work orders and materials, vendor manuals.
monitoring and maintenance Leverage performance content provided to help drive increased
execution extending the value of decision support and EAM maintenance execution
SAP EAM. had automatically alerted that there was a Preventative
Maintenance Notification and operations
Manufacturing xMII
Execution Plant User Interface
Performance and Portal
provides intelligence
over the performance
data. xMII can monitor
for asset performance
trends and trigger
alerts in SAP EAM Manufacturing EAM Mobile Target Users
such as a Maintenance Operations Maintenance Operations
Notification or Users Users and
dashboard before bad Maintenance
product is produced .
xMII provides
Users
integration with and
visualization of key
Production Intelligence
performance data from
plant level systems that
can then be viewed in
Production Integration SAP EAM Source Systems
VIP.
SAP ERP
********
********
Provides a centralized
view of all asset
content
by employing role-
based, simplified
functionality
Extends SAP PM to
streamline work
processes.
Unifies critical
functions and
information into xMII
one workspace
Portal-based solution
with over 50 iViews
provides speed-to-
value
Pepsico
Lack of timeliness, accuracy and consistency Ensure consistent aggregation, analysis and role-
in reporting across the organization based visualization
Key performance indicators (KPIs) applied Deliver timely, detailed, and accurate information
inconsistently across plants to empower production personnel for decision
making
High contract manufacturing costs because of Provide insight into data across enterprise and
less than acceptable plant efficiencies plants to improve performance