Content
SAP Digital Manufacturing
Manufacturing Execution with SAP DMe for discrete manufacturing
Chapter 1
The SAP Digital Manufacturing (SAP DM) solution is divided into two central components: SAP DMe (Execution) and SAP DM (Insights). What is SAP DMe in detail?
Chapter 2
SAP Digital Manufacturing includes a solution for the dispatching and monitoring of production orders at work center level: Resource Orchestration (REO).
Chapter 3
Workforce planning made easy: With the help of DMe and the Manage Labor application, the assignment of employees to production orders is also covered flexibly and reliably.
Chapter 4
A frequently discussed concept in the context of the digitalization of production processes: The so-called „digital twin“.
In this Whitepaper, we show you how to make the right decision for your specific application. In the context of the smart or digital factory, SAP Digital Manufacturing for Execution (SAP DMe) is as a SaaS manufacturing cloud solution that enables you to achieve significant benefits in quality and efficiency. As a result, visions and ideas relating to smart factory are increasingly becoming reality.
DMe as the central system in production
The MES solution SAP Digital Manufacturing (SAP DM) is divided into SAP DMi (Insights) and SAP DMe (Execution). We want to take a closer look at the latter. Let‘s start with the question: What is SAP DMe in detail?
SAP Digital Manufacturing for Execution (SAP DMe) is a cloud-based production control system that is based on the SAP Business Technology Platform and is used to control manufacturing activities at shopfloor level as dynamically and comprehensively as possible.
PROCESS-DESIGNER AND PRODUCTION OPERATOR DASHBOARDS
Using the Process Designer, even highly complex manufacturing processes can be mapped with the assistance of a graphical user interface, taking into account various potential scenarios. Various machine types can be fully integrated. This reduces production costs while improving product quality and manufacturing efficiency. Intuitive operator terminals - so-called production operator dashboards - are used to display relevant information, such as work instructions to guide the production workers through the assembly process.
This woker guidance can take the form of text descriptions, photos or videos or even an interactive 3D model that visually describes the assembly process. This makes the
use of paper redundant and paperless production, in which all data is recorded with system support, becomes reality. DMe also fulfils a central integration task and ensures a bidirectional, vertical communication between the ERP or S/4 system and the executive level of a plant. This enables the creation of an intelligent factory. With the SAP MES system acting as a link, the planning of production orders carried out at the administrative level (top floor) can be transferred to production.
DYNAMIC RESPONSIVENESS USING REO
SAP‘s answer to the considerable need for flexibility: the Resource Orchestration (REO) component contained in DM.
„
However, the production environment is usually characterized by enormous dynamics. Planning often has to be adapted to the situation or the priority of certain production orders frequently has to be adjusted in order to to meet the agreed delivery date. If the worst comes to the worst, the necessary tools may be defective or employees who are needed for the production of certain products may not be available at the required time.
In addition to the administrative planning of production and the actual execution, there is a considerable need for flexibility in order to be able to react to unplanned events and maintain a plant‘s productivity at a high level. SAP‘s answer to this challenge is the Resource Orchestration (REO) component contained in DMe, which is made up of the two main applications Dispatching and Monitoring and Manage Labor.
„With the Process Designer, even highly complex manufacturing processes can be mapped with a graphical user interface.“
Resource orchestration at shopfloor level
The Manufacturing Execution System SAP Digital Manufacturing includes a component for the dispatching and monitoring of production orders at work center level: Resource Orchestration (REO).
Resource Orchestration (REO) is used, among other things, to ensure flexible execution and situational reprioritization of individual production orders within the production planning specified by the ERP system. The so-called Dispatching and Monitoring Application enables users to react to special change requests from customers or fluctuations in demand, even at short notice - without affecting production output.
COMPLETE OVERVIEW OF RESOURCE STATUS
For this purpose, the respective availabilities of machines, employees and tools are visualized on a central interface in the form of a Gantt chart. This gives production managers a complete overview of the status of all resources. They can monitor both the progress of an order and the expected time of completion in real time. With the help of the REO component, changes can be easily and flexibly incorporated into the production planning specified by the ERP system using drag & drop and automatic support.
THE DISPATCHING AND MONITORING APPLICATION SUPPORTS MANUFACTURERS IN THE FOLLOWING AREAS:
Effective detailed planning and monitoring of events at shopfloor level
Comprehensive information on resource utilization and the current production situation thanks to a detailed notification concept
Visual representation of high-priority processes and orders
Fast response to unexpected events incl. AI support
Automatic scheduling of operations and optimized detailed planning (e.g. with heuristics or machine learning)
Splitting production orders between different resources
Manage Labor takes into account individual qualifications and certifications, for example, to ensure that only employees with the required expertise are assigned.
Dynamic workforce scheduling with SAP DM
Workforce planning made easy: With the help of DM and the „Manage Labor“ application, the assignment of employees to production orders is covered flexibly and reliably.
In addition to order dispatching and monitoring, DMe also manages the effective deployment of the employees involved: While shift planning in many companies is based on rigid rhythms and changes lead to a great amount of effort, the Manage Labor application enables flexible personnel planning in production.
Manage Labor takes into account a wide range of criteria, such as legal regulations on working hours. This ensures that resting periods and absences - for example due to illness or vacation - are automatically considered into shift planning. Individual qualifications and completed certifications and their validity are also taken into account so that certain production orders, for example, are only assigned to employees who have the necessary expertise. Experienced employees may run less risk of causing disruptions or being overwhelmed by complicated tasks. This is reflected in a smooth production process and optimal product quality.
The „Manage Labor“ application can be used by production managers for the following areas:
Planning and assignment of employees to shifts
Shift planning with online capacity view
Direct integration for detailed order planning
Online check of employee qualifications and certifications
Online check of vacation and absence times
„Digital twin“ and other functionalities
Workflows can be used to start processes automatically depending on events or conditions.
In addition to the two central modules Dispatching and Monitoring and Manage Labor, there are other DMe functions that can be used to further advance the automation of production. One frequently mentioned concept in the context of production process digitalization is the so-called „digital twin“.
Would you like to learn more about SAP DMe?
SAP DMe offers users extensive reporting and analysis options in order to congruently transfer all events within production to the digital world. To this end, all components and batches used as well as the production process itself are fully documented.
If errors or non-conformities occur, a corresponding deviation code (NC code) is generated during production. Optionally, additional data can be entered in the form of comments to record the causes of a deviation and other information in text form. The as-built report allows all details of all used parts to be subsequently traced using a shopfloor control number (SFC) and easily called up for quality checks or audits.
INCREASED PROCESS RELIABILITY
Workflows can also be used to start processes automatically depending on certain events or under predefined conditions. In this context, it is also possible to trigger pre-configured warnings, follow-up activities or alarms in certain scenarios. This leads to significantly higher process reliability within production. Production employees
are explicitly notified of errors and are also informed of the measures that can be taken to rectify the fault in question. With these functionalities the operational module DM provides manufacturing companies various tools to increase the efficiency of their production. The main focus here is on the dispatching and monitoring of orders using the REO component and the flexible shift planning of employees within a plant. However, SAP MES also takes topics such as traceability and reliable process management into account to ensure consistentquality. In addition there is a considerable degree of flexibility thanks to the intuitive Process Designer, which means that ever smaller production quantities down to batch size 1 can be produced profitably.
CONTACT US FOR FURTHER INFORMATION!
Do you still have questions? Or would you like more information about SAP Digital Manufacturing (SAP DM)?
If you are currently working on the digitalization of your production processes, please contact us. We will advise you and explain how we have already solved demanding challenges in the production environment based on SAP standard software together with our customers. We look forward to hearing from you!
YOUR CONTACT PERSONS Petra Zimmermann Sales
Copyright © 2023, IGZ Ingenieurgesellschaft mbH.
All rights reserved
Publisher: IGZ Ingenieurgesellschaft mbH
IGZ Ingenieurgesellschaft für logistische Informationssysteme mbH Logistikweg 1
95685 Falkenberg
Tel.: +49 9637 9292 - 0 | info@igz.com | www.igz.com