Speaker: Klaus Siegemund (Ferrero) Co-Speaker: José Iglesias (Ciber) Oktober Page 1

Transcription

1 at Speaker: Klaus Siegemund (Ferrero) Co-Speaker: José Iglesias (Ciber) Oktober Page 1

2 Need for a 360 view on manufacturing Source: SAP AG Page 2

3 Users don t care about systems and applications Source: SAP AG Page 3

4 Ferrero Group Facts Start as a pastry shop in Alba (Italy, Piemont) 1946 Company founded in Italy by Michele Ferrero Today global, non-listed company Since its foundation in family ownership: CEO Giovanni Ferrero The Ferrero Group in figures: ~ 30,000 employees 22 plants and 46 business units Turnover 2013: 8 Billion Page 4

5 Worldwide Plants Polen Deutschland Belgien Kanada Irland Russland Frankreich Italy (4 Plants) Türkei China Mexiko Kamerun Indien Ecuador Südafrika Sri Lanka Australien Argentinien Brasilien Page 5

6 German Plant Stadtallendorf Gate Chocolate Factory R/P Wh. FG Warehouses Power Plant First and largest production site of Ferrero outside Italy Workforce average of 4,000 employees Areal has size of 634,000 square meter in total High-Bay warehouse capacity for 70,000 pallets, expansion to 90,000 in 2016 Worldwide Export Page 8

7 Ferrero Brands Page 9

8 Page 12

9 MII in Production and Quality Management Time Mgmt. QM Dashboard MES Realtime Production Lines QM IPC Quality Control Seite 13

10 Integrating Automatic Palletizer with MII Packing Machine Scanner Packing Machine Palletizer Applicator Order + Schema MII Web Page (display on panel-pc) WINCC PLC PCo SAP (ERP) DB Show Orders Select Order Order MII Details Seite 14

11 Demand to implement EM As is situation New Horizons Page 15

12 Simply define your requirements How shall we begin? Simple! Page 16

13 Energy Management is embedded Human Capital Organization Idea Management Dashboard SAP BI Mobility Energy Management OEE Production Efficiency Predictive Maintenance SAP ERP Budget / Investments Preventive Maintenance MES / SF* Operations Productive Maintenance Continuous Improvement * Shop-Floor Page 17

14 Main Intentions Increase energy efficiency in our group Comparison between production lines Tool for identifying potentials for savings Benchmarking our own energy improvements Overall Corporate Energy Balance Profitcenter responsability Compare historical periods Budgeting process integration Cost controlling - Energy cost per product / cost center Evidence of Green Production Page 18

15 Expectations One central solution covering all functions Substitute EXCEL and other island solutions International standards and KPI Flexible business reports Dynamic report creation by user Minimum effort for configuration Good performance based on high data volume Stable and complete data transfer all over the chain Less data layers / interfaces High integration potential Open to OEE, Maintenance, Financial, Controlling Page 19

16 Different Types of Measurements Primary Electric Power (by Source) Gas Oil. Secondary Compressed Air Steam Fresh Water (different temperatures) Waste Water Page 20

17 Demand to implement EM As is situation New Horizons Page 21

18 Current Solution Page 22

19 Landscape Shop-Floor (Germany) Frako Server Frako Server Frako Server Counter ~ 800 electrical High Power Bus Transformer Siemens WINCC Concentrator (security level) Powerrate for WinCC non counted kwh Counter ~ 150 non electrical Compressed Air Steam operational Database SQL-Server MII Page 23

20 Landscape Shop-Floor Transfer rate 15 min EDMS Interface ProfiNet / Ethernet Systems Concentrator Sub system PLC Power Rate Acquisition Systems Sub system Priv. Fieldbus Acquisition Devices Ethernet/Field -bus Acquisition Devices Ethernet/Field -bus PLC Power Rate Up to 6 FIFO buffers for one S Each buffer is able to buffer 20 measuring points for one day when the EDMS is not available Page 24

21 Local Landscape External SAP ECC PP-PI Manual Input QLI Pieces Run- and Idle time PI Webservice MII SOAP XML Webservice EC EEM BWU MES EDMS Siemens Data accumulated 15 base INFO Cube operational Database SQL-Server Local Page 25

22 Global Landscape ECC GEA From ECC Central Instance BI Turkey Local Plant Systems PI GEA Group System MES Operational Database SQL-Server TUR Data MII XI Proxy EC-EEM Mexico Historian GER + ITA* MES *temporary tagnames Operational Database SQL-Server MEX Data tagnames Operational Database SQL-Server GER Data tagnames MII PI OHG Mapping Prod. Data Tag-list async Propagate Tagnames Back to other MII and ECC MII sync Italy Historian Operational Database SQL-Server Plant Data tagnames MII ECC OHG From ECC Local Instance Page 26

23 Example Daily Energy Report Page 27

24 Energy per 100 kg production output Page 28

25 Demand to implement EM As is situation Open new horizons! Page 29

26 Main Pillars approaching the future solution Energy Management 2.0 = Energy2Go MII on HANA HANA Near Real Time Integration Easy Analytics Mobility HTML Seite 30

27 Current System Landscape Simplification 0,000 Meter Data Meter Management System OPC MES PCO SSCE MII EM BI HANA Seite 31

28 System Landscape Simplification 0,000 Meter Data Meter Management System OPC MES PCO MII EM BI SSCE* 0,000 Meter Data Meter Management System OPC MES PCO MII HANA BI *SSCE = Self Service Composition Environment Seite 32

29 HANA EM 2.0 Reporting View Integration Scenario Big Data High Performance availabiliity with MII 15.x Custom Applications Reporting on MII with SSCE PIC Services Interfaces Standard - SW Lumira BI Design Studio Office Integration (EXCEL) HANA DB Seite 33

30 MII on HANA EM 2.0 BI Operational View Control Center Dashboards MES System (if in place) WINCC MII(Version independent) (if in place) 15' Buckets MII 15.x On HANA OPC PCO Scada PLC HANA DB "traditional" Databases Historian Seite 34

31 Central MII 15.x on HANA Integration View PIC Page 35

32 Strong SAP ERP integration Master Data stored in ERP Basic settings SAP ERP PM PP. Master Data Production Cost Center Products MII System Full Global Modules Meter Config Company data PIC = Plant information Catalog Seite 36

33 Plant Integration Ferrero Plant MII Systems MII System Full Global Modules PI PI MII System LOCAL Function Modules MII System LOCAL Function Modules MII System LOCAL Function Modules MII System LOCAL Function Modules Seite 37

34 POC Progress System Design Process Concept with SAP BBP finalized HANA design finalized Ongoing Tasks Co-Innovation Tasks with SAP ongoing Continous approval with stakeholders Continous POC systems improvements Build additional HANA DB, Views Loading Test Data (~ 30th June, 2015) POC Evaluation Page 38

35 Project Schedule n - Apr May - Aug Sept - Dez Jan - Apr May - Aug Sept - Dez MII Upgrade Concept Phase HANA Setup POC Evaluation Page 39

36 HANA Tools - Power Designer Page 40

37 SAP Hana Studio Seite 41

38 Reporting Example with LUMIRA Seite 42

39 Reporting Example with LUMIRA Seite 43

40 Reporting Example with LUMIRA Seite 44

41 Benefits Very simple: All improvements and constant opimization is finally saving our Job's because we are competitive despite high labor costs in Germany Seite 45

42 Thank you! Page 46