Batch Manufacturing with SAP MII

Batch manufacturing with SAP MII delivers best practice, preconfigured templates for the following application areas: role-specific manufacturing operations cockpits, manufacturing order list, material identification, work instructions, quality control, production confirmation, shift book, monitoring and logging, as well as manufacturing performance.

PRECONFIGURED TEMPLATE DETAILS:

Manufacturing Operations Cockpit
The preconfigured, role-specific cockpits provide real-time insight into activities and important key performance indicators (KPIs), as well as quick access to relevant applications and information. Manufacturing operations cockpits are delivered for the production supervisor, shift supervisor and shop floor operator, and serve as the entry and overview application for the user. They bring together the central applications the user works with (i.e. manufacturing order list, shift book messages and instructions), role-specific KPIs with drill-down capabilities, as well as URL links to additional solutions and websites.

Manufacturing Order List
The manufacturing order list provides a convenient overview of scheduled process orders and important order details (process order number, short text, status, scheduled start date and time, material number, short text, etc.). Users have the complete overview on one screen and can select an order from the list to process material identification or start the work instructions for order execution.

Material Identification
Material identification is a mobile solution to support shop floor operators check the correctness and completeness of materials staged for production for a specific process order. Operators simply select a process order (to display the corresponding material list) and scan the material barcodes with their handheld. The pre-built interfaces for communication between handheld devices, SAP MII and SAP ERP enable seamless integration and further processing of the barcode information. The material and batch number are automatically checked by the system for correctness. After completing material identification, the operator can start process order execution.

Work Instructions
The work instructions template integrates manufacturing enterprise, operations and shop floor data to support comprehensive task and process control, as well as process documentation. It provides an intuitive, easy-to-use application to take operators step-by-step through production execution for the selected process order. Work instructions provide operators all the necessary information, instructions, as well as comment and data entry fields (with automatic data validation) they need to support efficient process order execution - from safety instruction review, phase execution, in-process quality control and process order confirmation - all with digital signature support. Thanks to the pre-built integration with SAP ERP, work instruction data is sent to SAP MII via the control recipes. Furthermore, actual process values entered in the work instructions are sent to SAP ERP to ensure accurate update of batch and order records, the process order, as well as goods issue/receipt and order settlement. Likewise, SAP ERP quality management inspection lots are updated with the confirmed inspection data.

Quality Control
This template provides shop floor quality control with a straight-forward application to support result recording (outside of the work instructions application), as well as make usage decisions. Leveraging the integration with SAP ERP Quality Management, all required inspection lot data (including inspection operations, characteristic tolerance limits, eventual predefined drop-down menu result entries, inspection result valuation and usage decision options) are made available to the SAP MII quality control application. For results recording, the user simply selects the inspection lot and relevant operation, and then has all the information on one screen to record inspection results (with automatic tolerance validation), add comments (i.e. for defect documentation) and perform evaluation. The quality technician can then review the recorded inspection results and make an appropriate usage decision. The results, valuation and usage decision recorded in SAP MII are automatically sent to SAP ERP to update SAP Quality Management.

Production Confirmation
Production confirmation is designed for process orders that are not executed via the work instructions application. It provides operators with a lean, straight forward application to confirm process orders and post goods issue of produced materials. Operators simply choose a process order from the order list and select confirmations or goods movements to quickly record needed information i.e. actual quantities, batch number, date and time, etc. Confirmation data is checked automatically for plausibility and validity with regards to tolerance limits, and sent to SAP ERP to update the process order and goods issue/receipt.

Shift Book
The easy-to-use shift book application supports accurate shift set-up, as well as comprehensive management and reporting of shift activities, information, events and messages. Shift master data maintenance provides the shift supervisor with comprehensive tools to set up the shift structure and define shift plans (including factories, shift teams and workers, shift dates). Shift supervisors can use the shift instructions to provide relevant information to shop floor operators (i.e. tasks, due date and times). Furthermore, the shift notes capability enables manual entry, classification and documentation of important production messages and events during a shift. Finally, the shift hand-over report provides a summary of the shift messages and instructions.

Monitoring and Logging
Monitoring and logging automatically captures all relevant activities in batch manufacturing with SAP MII applications and stores them in log files. The log monitor enables users to retrieve information from these log files to track and trace system and user actions. Log files are classified according to severity (information, warning, error or critical messages) and can be easily filtered to support quick message finding, selection and subsequent drill-down for problem detection and root-cause analysis.

Manufacturing Performance
Manufacturing performance delivers reporting and key performance indicator (KPI) tracking. Role-specific KPI views provide predefined KPI calculations - for plant on-time delivery, production plan adherence, etc.. They support easy data selection (for example, via time-frame, resource, material or cost-centre), graphical KPI display (i.e. gauge, line and bar charts), and drill-down to base values for detailed analysis. Finally, the manufacturing performance template delivers a production report providing a list of process orders with their status.

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