Solution in Detail Manufacturing
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ETO and Project Manufacturing
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Simplifying Complex Manufacturing Managing Complex Manufacturing Enabling Complex Builds
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.
Improving Processes SAP Innovations 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 technology, cybersecurity, and multiplatform, multinational IT support. But these innovations are not always fully integrated, which means that manufacturing processes are suboptimal.
Incorporating new technology to compete in the evolving marketplace is critical. The engineerto-order (ETO) process supported by SAP software allows for definition of each customer’s 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.
This environment is complicated by the need to comply with expanding government and industry oversight. © 2013 SAP AG or an SAP affiliate company.
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Integrated Answer for Complex Builds Managing Complex Manufacturing Enabling 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.
Improving Processes SAP Innovations
39% Lower manufacturing cycle time where quality system has simplified data sharing and integration of inspection planning with related applications
Accelerate the design-to-delivery cycle by effectively managing complex designs. Comprehend 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.
Source: SAP Performance Benchmarking © 2013 SAP AG or an SAP affiliate company.
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Proficient Manufacturing Control Managing Complex Manufacturing Enabling Complex Builds Improving Processes
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:
SAP Innovations
47% Lower manufacturing cycle time for organizations in EMEA where control of processes is through pullbased production schedules
Reduced change incorporation cycle time
Accelerated design-to-delivery cycle
Improved manufacturing profitability
Improved accuracy of finished products
Reduced quality and compliance costs
Source: SAP Performance Benchmarking
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SAP Innovations Managing Complex Manufacturing Enabling Complex Builds
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 designto-market.
Improving Processes SAP Innovations Manufacturing innovations are providing new ways to reduce costs throughout the business: Analytics solutions help optimize all a reas 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 accomplish 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 manufacturing, 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 company’s diverse departments to center on the product. The resulting quality, operational productivity, and time-to-market improvements increase a company’s competitive advantage. © 2013 SAP AG or an SAP affiliate company.
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ETO Software Spans Manufacturing Needs Solution Overview Process Planning, Scheduling Visual Manufacturing Project Manufacturing Manufacturing Execution ETO and Project Manufacturing Why SAP?
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-tomanufacturing 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.
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Managing Complex Manufacturing Solution Overview Process Planning, Scheduling
Process Planning, Scheduling
Visual Manufacturing
Project Manufacturing
Manufacturing Execution
Manufacturing Business Operations
Define Planning
Define Product
Define Product Life Cycle
Manage Released Orders
Plant Operations
Resource Planning
Maintain Product Structure
Capacity Leveling
Maintain Resources and Tools
Production Operations
Maintain Orders
Display Product and Process Structure
Visual Manufacturing Project Manufacturing Manufacturing Execution ETO and Project Manufacturing Why SAP?
Display and Execute Orders
Engineer-to-order processes leverage project, definition, and execution functionality to synchronize all aspects of a product’s manufacturing cycle. © 2013 SAP AG or an SAP affiliate company.
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Process Planning and Scheduling Solution Overview Process Planning, Scheduling Capabilities Benefits Technology Innovation
Integrate BOMs with text, tools, and graphics to create and maintain shop work and tool maintenance instructions for manufacturing, rework, and maintenance.
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).
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Document and Maintain Process Plans Solution Overview Process Planning, Scheduling Capabilities Benefits Technology Innovation
Conform with engineering requirements while smoothly integrating parts and visual graphics, specs, tools, and related documents. Manage production resources for manufacturing, 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 instru ctions to assist in verifying compliance with internal, customer, and government requirements. Update work in process (WIP) where needed due to engineering or manufacturing requirements.
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Solution Overview Process Planning, Scheduling Capabilities Benefits Technology Innovation
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Integrated Solution for Managing Complex, Changing Products Reduce planning errors and product lifecycle costs with consolidated, standardized, intuitive, integrated graphical planning and data storage for simplified production processes.
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.
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Innovations in Process Planning and Scheduling Solution Overview Process Planning, Scheduling Analytics solutions are now available Capabilities
that can revolutionize manufacturing.
Benefits Technology Innovation
Analytics solutions enable advanced mode ling and optimization throughout production, from assessing resource utilization and improving productivity to monitoring detailed stocking information and measuring work-center performance.
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Visual Manufacturing Solution Overview Visual Manufacturing Capabilities Benefits Technology Innovation
Use intuitive 3D visualization to create, maintain, and communicate process plans, bills of material, and work instructions. Graphically query and maintain multilevel product structures.
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
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.
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Enable Efficient Manufacturing Solution Overview Visual Manufacturing Capabilities Benefits Technology Innovation
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.
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Solution Overview Visual Manufacturing Capabilities Benefits Technology Innovation
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Accelerate Comprehension and Consolidate Product Knowledge Simply and quickly access and maintain multilevel product structures in an intuitive graphical manner. Enhance understanding and eliminate unnecessary duplication of effort for complex structures. 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 products. 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.
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.
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Innovations for Visual Manufacturing Solution Overview Visual Manufacturing Capabilities Benefits
Production is simplified through use of mobile platforms that allow devices to display instructions and provide analytics.
Technology Innovation
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 manufacturer’s needs.
Metadata associated with the graphics can be displayed using the solution and can be queried using business analytics tools.
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Project Manufacturing Solution Overview Project Manufacturing Capabilities Benefits Technology Innovation
Structure a project from initial customer quotation through production project scheduling. Manage work breakdown, scheduling strategies, and project capacities.
Use project manufacturing functionality to manage long production cycles from product definition through shipping, including quotation and production phases.
Take advantage of advanced project and product scheduling, constraint-based production schedules, and interactive simulation for what-if scenarios.
Use work breakdown structures (WBS) to define project tasks, materials, resources, and capacities for logistical planning and execution.
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.
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Manage Complex Product Build Cycles Solution Overview Project Manufacturing Capabilities Benefits Technology Innovation
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 project’s lifetime.
Templates are available to accelerate structuring for both work breakdown and networks. Various methods of analysis and scheduling strategies are supported, including backward/forward, finite/infinite resources, and dates in the past allowed/forbidden.
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Solution Overview Project Manufacturing Capabilities Benefits Technology Innovation
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Efficient Planning Improves Complex Manufacturing Activity Leverage the advanced planning and scheduling functionality for project manufacturing to manage and streamline overall activities related to complex custom sales orders.
Project scheduling functionality simplifies and integrates scheduling using interactive, intuitive tools. This provides users with current, accurate visibility into project and product scheduling, identifying constraints early in the development lifecycle, improving production and request for quotation/request for proposal processes.
Resource allocation is enhanced with interactive 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.
Multiple scheduling strategies are available to remove backlog and improve planning results. Key performance indicators (KPIs) are monitored, including lead time and delay. © 2013 SAP AG or an SAP affiliate company.
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Innovations for Project Manufacturing Solution Overview Project Manufacturing Capabilities
SAP innovations improve complex assembly performance across the enterprise.
Benefits Technology Innovation
Analytics and graphics solutions enable advanced modeling and optimization throughout every aspect of the manufacturing network, from assessing current downstream demand to improving new product launches.
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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Manufacturing Execution Solution Overview Manufacturing Execution Capabilities Benefits Technology Innovation
Manufacturing execution for complex assembly efficiently manages shop-floor product and processes, scheduling priorities, quality management, and as-built records.
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.
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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Manage and Document Shop Activity Solution Overview Manufacturing Execution Capabilities Benefits Technology Innovation
WIP documentation, including production and rework orders, manages each worker’s 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.
Performing first articles, managing timesensitive material, and tracking orders through production are supported.
Data collection and serialization are integrated, stored, and archived with work instructions.
Nonconformance management controls shop quality.
Contract tool manufacturing and maintenance activity and listing in shop orders are available.
As-built BOMs graphically display the structure of components and assemblies as they are completed.
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Integrated Solution Manages Complex, Changing WIP Solution Overview Manufacturing Execution Capabilities Benefits Technology Innovation
Reduce cycle times and order processing costs with efficient execution features. Minimize rework and repairs. Reduce inventory. Assimilate users quickly through intuitive interfaces.
Management of activity by predefined worker privileges and certifications to match defined production order tasks simplifies the management 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 comprehension of the written word. This is extremely useful in high-turnover, multilanguage shops.
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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Innovations in Manufacturing Execution Solution Overview Manufacturing Execution Capabilities
Analytics solutions can now be combined with mobile solutions to revolutionize manufacturing.
Benefits Technology Innovation
Analytics solutions enable advanced mode ling and optimization throughout production, from assessing resource utilization and improving productivity to monitoring detailed stocking information and measuring work-center performance.
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
.
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Engineer-to-Order and Project Manufacturing Value Map Solution Overview Process Planning, Scheduling
Make-to-Order Manufacturing
Production Planning and Scheduling
Quality Planning and Control
Manufacturing Execution
Performance Visibility and Monitoring
Repetitive Manufacturing
Production Planning and Scheduling
Quality Planning and Control
Manufacturing Execution
Performance Visibility and Monitoring
Engineer-to-Order and Project Manufacturing
Process Planning and Scheduling
Visual Manufacturing Engineering
Project Manufacturing
Manufacturing Execution
Lean Manufacturing
Production Planning and Scheduling
Lean Six Sigma Analysis
Poka Yoke Processing
Manufacturing Execution
Outsourced Manufacturing
Collaborative Manufacturing
External Processing
Subcontracting Core
Quality Management and Compliance
Corporate Quality
Quality Planning and Control
Quality Operations
Visual Manufacturing Project Manufacturing Manufacturing Execution ETO and Project Manufacturing Why SAP?
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Why SAP? Solution Overview Process Planning, Scheduling
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.
Visual Manufacturing Project Manufacturing Manufacturing Execution ETO and Project Manufacturing
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.
Why SAP? 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.
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Solution in Detail Manufacturing
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