Ewm210 Full (Secured)

I n t e r n a l U s e S A P P a r t n e r O n l y
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S A P
S A P
SAP EWM 210_1
P a
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Material Flow System
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Overview
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SAP EWM Extended Warehouse Management

Curriculum
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O n
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SAPSPM 2 days EWM100 3 days EWM110 5 days EWM120 5 days
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a
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SAP Service Parts Extended Warehouse Extended Warehouse Additional Features in
l
Management Management Management Extended Warehouse
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Overview Customizing Management

t
U
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a
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EWM210 3h
P
S A P
(MFS) in EWM
S A P
EWM220 2h
P a
RadioFrequency
s e
Framework (RF)
in EWM
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t
Clasroom training
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EWM230 2h
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Recorded clasroom training
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ITSMobile
r
& RadioFrequency
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in EWM
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Agenda
What MFS Is Good For & How It Works
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O n
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1. Which business needs are addressed by MFS?
n
t
U
r
s
2. EWM and MFS - How are they integrated?
a
e
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S A P
3. What are the basic concepts of MFS?
S A P
4. Which kind of equipment may be integrated and which not?
P a
s e
5. How complicated is it to implement it?
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6. How can it be tested?
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7. What should be considered when deciding for MFS?

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Business Needs Addressed by MFS

Customer Perspective
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l y
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O n
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 Directly connect SAP to the shop floor
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n
SAP ERP SAP ERP
r
a
 Control stacker
cranes and conveyors
e
l
n
without needing an external material flow

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U
r
system
s
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SAP WM SAP EWM

 Reduce the number of interfaces
S A P
S A P
 Have
only 1 responsible for warehouse
management and material flow system
P a
s e
r
 Take
benefit of SAP system landscape for SAP MFS
U
3rd Pty.
t
n
material flow layer MFS
l
e
a
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n
SAP PCo
 Have a well integrated material flow control
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O
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 Reduce license cost and maintenance fee
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PLC PLC
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Business Scenario – High Rack Warehouse for

Pallets
Aisle 1 Aisle 2 Aisle 3
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l y
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O n
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Crane2
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n
r
Crane3
a
High rack storage bins
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a
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S A P
S A P
Crane1
P a
s e
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Conveyor System
TCAR
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Transfer Car
e
a
r
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ID Point Put away Removal-HU

r
O
Put away Pick-HU
e
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t
l
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y
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Pick Point
Full pallets
Pick-HU
Goods Receipt Clearing Goods Issue Empty Pallets

Requirements – ID Point
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l y
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O n
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Crane2 Crane
r
available?
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r
Crane3
a
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U
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s
a
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P
Cross load
S A P
products /
S A P
Crane1
batches to In feed
aisles conveyor
P a
s e
capacity?
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U
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n
Conveyor System
TCAR
l
Transfer Car
e
a
r
n

HU Type?
r
O
Put away Pick-HU
e
n
HU
t
l
n
y
warehouse
I
conform? Pick Point

Full pallets
Pick-HU

Requirements – Cranes
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l y
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t
O n
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Crane2 Task
r
interleaving!
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r
Crane3
a
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Task
l
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Priorities.
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U
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s
a
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P
S A P
S A P
Crane1 Drop point

available?
P a
s e
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U
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Conveyor System
TCAR
l
Transfer Car
e
a
r
n

r
O
Put away Pick-HU
e
n
t
l
n
y
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Pick Point
Full pallets
Pick-HU

Requirements – Transfer Car
I
l y
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t
O n
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Crane2
r
n
r
Crane3
a
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l
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t
U
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S A P
S A P
Crane1
P a
s e
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U
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Conveyor System
TCAR
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Transfer Car
e
a
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Task Interleaving. ID Point Put away Removal-HU

r
O
Put away Pick-HU
Task priorities.
e
n
t
l
Drop point
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available? Pick Point

Full pallets
Pick-HU

Requirements – Capacity Event Triggering
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l y
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O n
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Crane2
r
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HU 4
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Crane3
a
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l
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t
U
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s
Make efficient use
a
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of conveyor
S A P
capacity and
S A P
Crane1 HU 3
resources
P a
s e
HU 2
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Conveyor System
TCAR
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Transfer Car
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a
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ID Point HU 1 Put away Removal-HU

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Put away Pick-HU
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Pick Point
Full pallets
Pick-HU

Business Scenario –
Programmable Logic Controllers (PLC)
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l y
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Crane3
t
O n
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PLC RACK3
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n
r
a
Crane2
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PLC RACK2
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s
Crane1
a
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P
S A P
PLC RACK1
S A P
P a
s e
EWM
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TCAR
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IP
PLC CONSYS1
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O
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PP
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Clearing GI
GR
Responsibilities
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EWM
l y
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• Routing to final destination: Divide HU warehouse
O n
e
task into several sub-steps according to PLC
r
n
communication points (CP).
r
a
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• Consider physical capacity of resources (CP,
l
n
conveyor segment, transfer car, crane)

t
U
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• Consider physical / logical state of resources (out
s
a
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of order, blocked)
P
S A P
• Routing to clearing in case of exceptions
S A P
P a
s e
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U
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PLC
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1
Scanner
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TCAR
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• Real time monitoring of sensors
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• Real time control of drives

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• Keep track of HUs from CP to CP
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• Read scanners
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• Support HU compliance check

(measure HU outline, measure HU
height, read weight from scale,
detect HU type) CP = Communication Point
EWM Controls Single Transportation Steps
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Aisle 1 Aisle 2
l y
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O n
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EWM
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Final
S A P
Destination
S A P
CP12
P a
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Intermediate CP11
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U
Destination
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1
Scanner
CP02
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TCAR
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CP01
a
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O
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Conveyor
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PLC
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Aisle 1 Aisle 2
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O n
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EWM
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Final
S A P
Destination
S A P
CP12
Intermediate
P a
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Destination CP11
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1
n
Scanner
CP02
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TCAR
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CP01
a
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O
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Conveyor
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PLC
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Aisle 1 Aisle 2
l y
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O n
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EWM
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P
S A P
S A P
CP12
P a
1
s e
CP11
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U
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Scanner
CP02
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TCAR CP01
a
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r
O
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l
Conveyor
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PLC
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Aisle 1 Aisle 2
l y
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O n
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EWM
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n
r
a
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l
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t
U
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s
a
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P
S A P
S A P
CP12
P a
s e
CP11
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U
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Scanner
CP02
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TCAR CP01
a
r
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r
O
e
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l
Crane1
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y
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PLC
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Aisle 1 Aisle 2
l y
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t
O n
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EWM Final
r
Destination
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a
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l
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U
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s
a
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P
S A P
1
S A P
CP12
P a
s e
CP11
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U
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Scanner
CP02
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TCAR CP01
a
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r
O
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Crane1
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PLC
Documents during HU Transportation
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EWM Warehouse Tasks
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O n
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CP1 Step 1 CP2 Step 2 CP3 Step 3 CP4
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n
1
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a
Warehouse Task 1
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2
t
Warehouse Task 2
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a
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Telegram 1 to PLC (Task)
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S A P
S A P
1
Telegram 2 from PLC (Task Conf.)
3
Warehouse Task 3
P a
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1
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O
Activation Warehouse Task 1
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Business Needs
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 Automated execution of warehouse tasks (move HU)
l y
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 First approach:
O n
e
r
 Pallets and other slow moving HU types
n
r
 Response time around 1 sec*
a
e
l
n
Two transactions per event

t
U
Confirm previous task (post HU to new bin)
r
1.
s
a
e
2. Create / select and communicate follow-up task**
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S A P
S A P
P a
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O
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* ID point (bin determination) may take longer.
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** To reduce PLC idle time the telegram is created and sent to the PLC before the WT is written to the database.
Agenda
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MFS Uses and Extends Existing EWM Objects
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EWM WO Queue Rsrc
t
O n
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r
PLC relevant
n
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HU WT
a
e
l
Rsrc
n
TELE PLC
t
U
r
s
BIN BIN
a
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P
S A P
S A P
CP CP Channel
MFS
P a
s e
Move HU from - to
r
U
t
PLC
n
l
e
Legend
a
WO – Warehouse Order
r
n
WT – Warehouse Task
r
HU – Handling Unit
O
e
CP – Communication Point
n
t
l
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y
CP
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CP CP RSRC
Warehouse tasks are communicated to PLCs if they are added to PLC relevant queues.
Task communication to PLCs is invoked by queue determination rules (customizing)
MFS Telegrams are Created for

Subsystem Relevant Queues
I
l y
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Source Storage Bin Warehouse Task Dest. Storage Bin
t
O n
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Bin Access
r
Activity Type Warehouse Activity
n
r
Area Process Type Area
a
e
Activity
l
n
Queue determination is
t
U
customizable
r
s
a
e
P
Queue Determination Criteria
S A P
S A P
P a
s e
r
Queue for Rsrc 01 Queue for Rsrc 02 Queue for Conv 01 Queue for Rsrc 03
U
t
n
l
e
a
r
n
Queues are PLC

r
O
CONV01
relevant by customizing
e
n
RSRC03
t
l
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y
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CONSYS1 CONSYS2 PLC or other sub system
PLC Telegrams Trigger MFS Function Modules

which Make Use of Standard EWM Coding
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l y
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O n
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n
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U
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s
a
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P
S A P
S A P
P a
s e
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U
Confirm task CP01-CP02
t
Create new task CP02 – CP11
n
l
e
a
r
n
r
O
e
n
t
WT HU1 from CP02 to CP11
l
WTCO HU 1 from CP01 to CP02
n
y
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HU 1 arrives at CP02 PLC
Warehouse Monitor
I
l y
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t
O n
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r
n
r
a
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l
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t
U
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a
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P
S A P
S A P
P a
s e
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U
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l
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a
r
n
r
O
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t
l
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y
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Customizing
I
l y
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O n
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a
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U
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S A P
S A P
P a
s e
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U
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a
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O
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Alerts & Application Log
I
l y
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EWM Alert Monitor
O n
e
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n
r
a
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t
U
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s
a
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P
S A P
S A P
P a
s e
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a
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O
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Detailed Analysis
I
l y
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EWM Application Log
O n
e
r
n
r
a
By Date / Time
e
l
n
t
U
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s
a
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P
S A P
S A P
P a
s e
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U
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a
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O
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Lesson 2 - MFS Integration
I
l y
n
 MFS is not a separate system with an additional interface
t
O n
e
 MFS uses existing EWM objects and coding and extends them by additional features for
r
n
 Telegram communication
r
a
e
 Background warehouse task execution with automated equipment
l
n
t
U
r
s
a
 Advantage
e
P
 Every EWM data available
S A P
S A P
– Physical situation for stock decisions (e.g. availability of cranes for put away or
picking strategy)
P a
s e
– Warehouse requests and stock data for routing decisions (load balancing between
r
aisles, delivery data for sorting)
U
t
n
 No data synchronization required between WM and MFS layer
l
e
a
r
 MFS layer comparably slim
n
r
O
 Disadvantage
e
n
t
l
 Runs on the same machine / database
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y
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 Performance and / or response times may be an issue
Agenda
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O n
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S A P
S A P
P a
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MFS uses EWM Layout Oriented Storage

Control
I
l y
n
Crane2
t
Crane3
O n
e
A single HU has to go several steps:
r
Crane1
From ... to ... via
n
r
a
e
Conveyor System
TCAR Transfer Car
l
n
Put away Pick-HU

t
U
Pick Point
Full pallets
r
Pick-HU
s
a
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P
S A P
S A P
P a
s e
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l
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a
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O
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Layout Oriented Storage Control Allows

Automatic Reaction to Material Flow Errors
I
l y
n
t
O n
e
r
n
r
a
e
l
Inactive task to final destination
n
LP LP
t
U
r
s
a
e
P
S A P
CP CP
S A P
Deviation
(Material flow error)
P a
s e
CP CP
r
New active task
U
t
n
l
e
Unexpected Scanner Message:
a
r
HU location is adjusted
n
New way is determined

r
O
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t
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y
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Material Flow Attributes are Extensions to

Storage Bins
I
l y
n
t
 Every MFS relevant conveyor location is modeled as a storage bin
O n
e
r
 Physical attributes of conveyor locations are kept in the new customizing object
n
r
Communication Point (CP).*
a
e
l
n
 Communication points are linked to storage bins (master data).

t
U
r
 The main CP attributes are
s
a
e

P
Capacity (number of HUs allowed at this location at a time)
S A P

S A P
Capacity mode (how to consider HUs, which currently are expected to arrive or
to leave this point, regarding capacity)
 Behavior in case of capacity bottleneck (create appropriate WT nevertheless or
P a
s e
not)
r
U
t
 Next CP direction clearing
n
l
e
a
r
n
r
O
e
n
t
l
n
y
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*also called “Reordering Point”

Telegram Interface - not IDOCs
I
l y
n
t
O n
e
r
n
SAP ERP SAP ERP
r
a
e
l
 Short, flat messages
n
t
U
 No meta data are transmitted (no structural
r
s
a
info except telegram type)
e
P
SAP EWM SAP EWM

 Fast
S A P
S A P
 No RFC library for PLCs available

 Best practice for warehouse automation EWM-WCU IDOC
P a
s e
r
3rd Pty. SAP MFS
U
t
MFS
n
l
e
a
r
MFS-PLC Telegrams
n
r
O
e
n
PLC PLC
t
l
n
y
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PLC Communication Protocol is Part of EWM –

Not of an External Communication Layer
Sender repeats a message as long as it isn„t acknowledged (every n secs.)
I
l y
n
Sender does not send a next message before the previous one has been acknowledged
t
O n
e
r
EWM
n
r
a
e
Send buffer Channel 1
l
n
No Telegram Snd Ack

t
U
17 State Request CP13 Y N
r
s
TASK CP02 – CP03
a
18 N N Last No. received 923
e
P
RFC Acknowledge
S A P
Telegram
S A P
Telegram
No. 17 No. 923
P a
PCo
s e
Acknowledge
r
Telegram Telegram
U
t
No. 17 No. 923
n
l
e
TCP/IP
a
r
n
Last No. received 17 Send buffer Channel 1

r
O
No Telegram Snd Ack
e
n
PLC 1 923 State CP13 Y N
t
l
CONF CP02 – CP03
n
924 N N
y
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Receiver sends an acknowledge message for every message he receives

Receiver processes a message only the first time he receives it
Systems are Connected via RFC Adapter:

“SAP Plant Connectivity” (SAP PCo)
I
l y
n
t
• To connect EWM with the PLCs a protocol
O n
e
converter RFC - TCP/IP is required
r
n
• This RFC adapter runs separate from SAP
r
a
e
and registers to SAP as an external RFC
l
n
destination (transaction SM59, RFC)

t
U
r
• This adapter doesn’t convert data. It simply
s
a
e
sets the data to another “rail”.
P
• It doesn’t keep track of the data. It doesn’t
S A P
S A P
RFC
even take any responsibility to deliver them
Windows to the receiver. And it doesn’t know anything
SAP PCo
P a
about the structure and meaning of the
s e
telegrams.
TCP/IP
r
U
• PLC IP addresses and ports are maintained
t
n
in EWM and passed to the adapter during
l
e
a
startup.
r
n
• For scalability reasons it is possible to use a

r
O
e
n
PLC separate adapter instance per warehouse
t
l
number and PLC.
n
y
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• The RFC-Adapter from SAP is called „SAP

Plant Connectivity“ (SAP PCo) and it runs
on Windows systems.
Interface to Connect non-SAP RFC Adapters

Available
I
l y
n
SAP PCo is restricted to
t
O n
e
 Windows OS
r
n
r
 No binary data in telegrams
a
e
l
n
 Telegram length < 256 byte

t
U
r
If PCo cannot be used an interface is foreseen to connect other adapters:
s
a
e
P
S A P
S A P
P a
s e
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U
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n
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e
a
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O
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Telegram Communication Implementation
I
l y
n
 MFS telegrams may be created by concurrent work processes.
t
O n
e
 To send a telegram each of these processes calls /SCWM/MFS_SEND
r
n
 This function module checks if there are unconfirmed telegrams in the send buffer
r
a
e
(/SCWM/MFSDELAY). If yes it adds the telegram to the buffer.
l
n
 If then an acknowledgement telegram is received for a previous telegram, the receiving

t
U
r
s
process (/SCWM/MFS_RECEIVE2) retrieves the next telegram from the buffer and sends
a
e
P
it.
S A P
 A background job called “telegram repetition process” is responsible to check if there is an
S A P
acknowledgment telegram outstanding for a long time (e.g. 3 sec.), and then to send it
again.
P a
s e
 The background process is started automatically on PLC channel startup per warehouse
r
U
number.
t
n
l
 PLC channels are started manually from the warehouse monitor.
e
a
r
n
r
O
e
n
t
l
n
y
I
Scalability
I
Several channels per PLC possible.
l y
n
Channels are working parallel.
t
O n
e
r
n
r
PLC 1 PLC 2
a
e
l
n
The telegrams of each Channel A Channel C Channel B Channel D

t
U
channel are transmitted
r
s
a
e
sequentially.
P
S A P
S A P
RFC RFC RFC RFC
Data transmission and
P a
data processing are
s e
decoupled by the
r
U
t
database.
n
l
e
a
r
n
The telegrams of each Function Function Function Function

r
O
channel are processed Module Module Module Module
e
n
t
sequentially.
l
n
y
Follow-up events are
I
triggered asynchronously.
Main influence to the performance:
Number of work processes.
MFS Coding Refers to an Overall Telegram

Structure
I
Internal Telegram Structure (Standard)
l y
n
t
O n
Internal
e
r
processing
n
r
a
e
Mapping by
l
n
field name
t
U
External
r
s
communication
a
e
P
S A P
S A P
P a
External Telegram Structure
s e
(subset for project)
r
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
Customer append structure for

non-standard telegram fields
Business Add-Ins Allow to Manipulate

Telegrams Close to the Interface
I
l y
n
t
O n
e
r
n
r
a
e
l
n
t
U
r
s
a
e
P
S A P
S A P
P a
s e
r
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
Customizing Allows to Invoke Non-Standard

Processing of PLC Telegrams
I
ABAP coding – standard or custom
l y
MFS customizing
n
t
O n
e
r
n
r
a
e
l
n
t
U
r
s
a
e
10 ZBD_AOUT_PROCESSING
P
S A P
S A P
P a
s e
r
U
t
Customer Name Space
n
l
AOUT 10
e
ZBD_AOUT_PROCESSING
a
r
•Make some extra work
n
•Call /SCWM/MFSACT_WT_CONFIRM with exception

r
O
e
n
WTCO HU 1 HB01-02-07-04
t
AOUT
l
n
y
PLC telegram
I
HU 1 not available for outbound request PLC1
Predefined Standard Telegram Types
I
l y
n
EWM
t
O n
e
r
n
r
a
e
l
n
t
U
Type Meaning Type Meaning
r
s
a
WT Warehouse Task (HU from - to) LL Location Left
e
P
TC Warehouse Task Confirmation
S A P
S A P
CR Cancel Request for WT CA Cancel Response success / denied

SR State Request for CP / Resource ST State Message for CP / Resource
SC Scanner Message (HU at CP)
P a
LF Life Check Telegram LF Life Check Telegram
s e
SY Synchronization Request SB Synchronization Begin
r
U
t
SE Synchronization End
n
l
e
a
r
Identifiers customizable
n
r
O
e
n
t
l
n
PLC
y
I
Telegram Types and Telegram Structures

Customizable
I
l y
n
t
Assign telegram type identifiers to
O n
e
predefined telegram categories
r
n
r
Assign telegram type specific
a
e
l
telegram structures
n
t
U
r
s
a
e
P
S A P
S A P
P a
s e
r
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
Lesson 3 – Basic Concepts
I
 Layout-oriented storage control
l y
n
t
 Telegrams, not Idocs
O n
e
Minimal technical scope “out sourced” to external communication layer (RFC adapter)
r

n
r
 Extendable overall telegram structure
a
e
l
n
 Flexible method invocation

t
U
r
 Be able to move exceptional HUs (unknown, no destination)
s
a
e
P
 Spread of responsibilities between EWM and PLC is flexible
S A P
S A P
 Standard functions* available for

 Warehouse task execution
P a
 Resource state communication (availability, capacity)
s e
r
 Scanners
U
t
n
 Communication startup
l
e
a
r
n
r
O
e
n
t
l
n
y
I
*Example MFS-PLC interface description based on these functions is available (sufficient for simple warehouses)
Agenda
I
l y
n
t
O n
e
r
n
r
a
e
l
n
t
U
r
s
a
e
P
S A P
S A P
P a
s e
r
U
t
n
l
e
a
r
n

r
O
e
n
t
l
n
y
I
Kinds of Equipments
I
 Conveyors
l y
n
 Pallet conveyors
t
O n
e
 Case conveyors – depending on performance requirements
r
n
 Scanners at conveyors
r
a
e
l
 Conveyor integrated stretchers
n
Printers, label applicators at conveyors – coding required

t
U

r
s
 HU sorters – depending on performance requirements
a
e
P
 Resources
S A P
S A P
 Cranes – single load

 Transfer cars – single load
P a
 Automated guided vehicles (AGVs) – as subsystem only (executes HU WTs, controls its vehicles)
s e
r
 Picking systems
U
t
 HU Pick robots – may be by EWM-WCU IDOC interface
n
l
e
HU storing systems (e.g. paternoster: Presents requested HU‟s at an operator port) - if they include the
a
r
n
picking user transaction: Same as picking robots. If not – project will come (Autostore in Norway).
r
O
Pick to light / pick by light – as subsystem including pick user transaction only
e
n
t
l
 Pick by voice – RF (not MFS)
n
y
I
 Packing systems
 HU packing robots – task from to, but without detailed packing instruction
Lesson 4 – Kinds of Equipments which may be

integrated
I
l y
n
t
O n
e
r
First approach:
n
r
HU task handling systems – communicate single warehouse tasks via MFS-PLC
a

e
l
telegram interface
n
t
U
 Order handling systems – communicate warehouse orders via EWM-WCU IDOC
r
s
a
e
interface
P
S A P
S A P
P a
s e
r
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
Agenda
I
l y
n
t
O n
e
r
n
r
a
e
l
n
t
U
r
s
a
e
P
S A P
S A P
P a
s e
r
U
t
n
l
e
a
r
n

r
O
e
n
t
l
n
y
I
Customizing Steps for PLC Link
I
l y
n
1. Define telegram structure
t
O n
e
r
2. Define interface type
n
r
a
e
3. Define telegram types and structures
l
n
t
U
r
4. Define PLC
s
a
e
P
5. Define communication channel for PLC
S A P
S A P
6. Define error codes (to be sent to PLC) and EWM exceptions (to be raised by PLC error codes)
P a
7. Create a RFC destination
s e
r
U
t
8. Maintain PLC: Assign RFC destination
n
l
e
a
9. Maintain communication channel: Assign IP address and port
r
n
r
O
10. Configure RFC adapter
e
n
t
l
n
y
I
Customizing Steps for Material Flow

with Conveyor Systems
I
l y
n
1. Define warehouse layout (storage type, storage bins, communication points)
t
O n
e
2. Define layout oriented storage control
r
n
r
a
3. Setup queues and queue determination
e
l
n
t
U
4. Setup task communication with PLCs
r
s
a
e
P
5. Customize capacity restrictions
S A P
S A P
6. Setup reaction to equipment faults
P a
7. Setup material flow triggers
s e
r
8. Deal with scanners
U
t
n
l
e
9. Introduce an automated identification point
a
r
n
r
O
e
n
t
l
n
y
I
Customizing Steps for Material Flow

with Resources
I
1. Connect a transfer car
l y
n
t
1. Define a queue
O n
e
2. Setup queue determination criteria
r
n
3. Define a resource type
r
a
e
l
4. Create a resource
n
t
U
r
s
2. Connect an automated high bay storage
a
e
P
1. Create high bay storage bins
S A P
S A P
2. Layout oriented storage control

3. Setup PLC and channel for the automated storage retrieval machines
P a
4. Define WT queues and queue determination criteria
s e
5. Define a resource type and create resources
r
U
t
6. Control interleaving (dual cycle movement for rack feeders)
n
l
7. Setup exception handling „Bin occupied“
e
a
r
n
8. Setup exception handling „Bin empty“

r
O
e
3. Stock removal in an automated warehouse
n
t
l
1. Full pallet removal
n
y
I
2. Picking
Agenda
I
l y
n
t
O n
e
r
n
r
a
e
l
n
t
U
r
s
a
e
P
S A P
S A P
P a
s e
r
U
t
n
l
e
a
r
n

r
O
e
n
t
l
n
y
I
Test with Physical Equipment is Expensive
I
 With automated equipment three layers have to be kept in sync:
l y
n
t
1. EWM/MFS
O n
e
r
2. PLC
n
r
a
3. Physics
e
l
n
 It is more complicated to prepare all three for a test

t
U
r
s
 Different parties have to wait for each other (especially in case of errors)
a
e
P
 Reduced test slots with physical equipment.
S A P
S A P
 No remote test with physical equipment.

 Load test needs a lot of preparation.
P a
s e
 If it is an existing warehouse (retrofit), additional issues for testing are
r
 Switch PLC from current WCS to EWM and back for testing
U
t
n
 Don‟t change physical situation for the current WCS by moving HU‟s with EWM.
l
e
a
r
n
r
O
e
n
t
l
n
y
Urgent need for a chance to test without physical equipment.
I
Not only before but also after going live.
Test Tool SAP PLC Emulation
I
• Emulates material flow and PCL interface.
l y
n
Test Production
t
• Allows test without real warehouse equipment.
O n
Environment Environment
e
r
• Allows performance test.
n
r
• Allows forcing errors.
a
e
l
n
• Allows to test the rest of EWM without being connected SAP ERP SAP ERP
t
U
to the real PLCs.
r
s
a
• Important quality factor.
e
P
• Is a service provided by SAP Consulting (not a SAP AG
S A P
S A P
product) SAP EWM SAP EWM

• To be calculated on top of MFS implementation.
SAP MFS SAP MFS
P a
s e
r
U
t
RFC-Adapter RFC-Adapter
n
l
e
a
r
PLC
n
r
O
e
n
t
PLC
l
n
y
Emulation
I
Real Life Test Scenarios

Example Goods Receipt Scanner
I
l y
n
t
Scanner 01SC0001Goods Receipt
O n
e
r
n
r
a
e
l
n
Create error message

t
U
Check HU OK? No Set HU exception
(height / weight)
r
HU moved to
s
EWM
Yes Post HU to WE02

WE02?
a
e
P
Yes
S A P
No
Teletype 51 Teletype 51 HU has exception
No Set HU exception DAS
S A P
Destination WE02 Destination WE01 already?

(Sorter) (Clearing)
Teletype 04
P a
HU 12345678 Teletype 11
s e
Height 01/02 DAS report

Weight 20,00kg
r
PLC
U
t
n
l
Collect weight, Control Conveyor Create DAS report
e
height, barcode
a
r
n
r
O
e
Material Flow
n
t
l
n
Scale Scanner
Height detector
y
01SC0001 HU
I
Performance Test with SAP PLC Emulation
I
l y
n
t
O n
e
r
n
r
a
e
l
n
t
U
r
s
a
e
P
S A P
S A P
P a
s e
r
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
Simulation versus Emulation
I
l y
Simulation is a design test tool.
n
t
O n
e
r
Emulation is a software
n
r
a
implementation test tool.
e
l
n
SAP EWM
t
U
r
s
a
SAP MFS
e
P
S A P
S A P
P a
s e
r
Simulation (e.g. Automod)
U
t
Emulation
n
l
e
Runs stand alone
a
r
(no connection to a host system). Runs connected to WMS.
n
r
Emulates WMS-PLC interface.
O
Simulates material flow.
e
n
t
l
Focus Focus
n
y
I
Determine bottle necks during Test WMS during warehouse

warehouse design. implementation and maintenance.
Adjust strategies.
Lesson 7 – Test
I
 PLC emulation as implementation test tool is crucial
l y
n
t
 Customers accept additional invest
O n
e
r
 Proof of concept
n
r
 Quality assurance
a
e
l
n
 Parallel testing (different warehouse numbers, different areas)

t
U
r
 Reduce risk for maintenance as well (process changes, notes, releases)
s
a
e
P
 SAP PLC emulation
S A P
S A P
 Flexible core available

 CSV table based (allows a lot of customizing including layout)
P a
 Java knowhow required
s e
r
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
Agenda
I
l y
n
t
O n
e
r
n
r
a
e
l
n
t
U
r
s
a
e
P
S A P
S A P
P a
s e
r
U
t
n
l
e
a
r
n

r
O
e
n
t
l
n
y
I
Interaction/Influencing Factors/Pressure
I
l y
n
t
O n
e
r
Undocumented legacy
n
r
system
a
e
l
n
t
U
Retrofit for vendor internal Inexperienced staff / not
r
s
MFS-PLC interface cooperating PLC vendor
a
e
P
S A P
S A P
Non standard equipments Risk
P a
7*24h
s e
e.g. label applicators, robots Time / Cost
r
U
t
n
l
e
a
r
n
Non standard
r
High Volume
O
communication protocol
e
n
t
l
n
y
I
Multi HU forks / multi deep
I
l y
n
t
O n
e
r
n
r
a
e
l
n
t
U
r
s
a
e
P
S A P
S A P
SAP EWM 210_2
P a
s e
r
U
t
n
l
e
a
r
n
r
O
e
Setup PLC Communication
n
t
l
n
y
I

Curriculum
I
l y
n
t
O n
e
r
n
r
a
e
l
n

t
U
r
s
a
e
EWM210 3h
P
S A P
(MFS) in EWM
S A P
EWM220 2h
P a
RadioFrequency
s e
Framework (RF)
in EWM
r
U
t
Clasroom training
n
EWM230 2h
l
e
a
ITSMobile
r
& RadioFrequency
n
in EWM
r
O
e
n
t
l
n
y
I
Agenda
I
l y
n
t
O n
e
r
n
r
a
e
1. Setup MFS PLC Communication Protocol
l
n
t
U
2. Maintain PLC master data
r
s
a
3. Internal Test with /SCWM/MFS_SIM_RECEIVE
e
P
S A P
4. Setup SAP PCo
S A P
5. Setup PLC Emulation Tool
P a
s e
r
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
MFS Objects
I
l y
n
t
O n
EWM
e
WO
r
n
r
a
e
WT Queue Rsrc
l
HU
n
t
U
r
s
a
e
P
TELE PLC PLC Link
S A P
CP CP CP
S A P
Segm
Channel
P a
s e
r
U
t
n
l
e
a
r
PLC
n
r
O
e
n
t
l
n
y
I
CP CP
CP RSRC
EWM Telegram Categories

Protocol Related / Material Flow Related
Usage
I
Telegram Type Telegram Category
l y
n
(customizable)
t
O n
e
 SYES  Synchonization Setup  EWM to initiate connection to PLC
r
n
r
a
 SYBE  Synchronization Start  PLC to start synchronization mode (answer to SYES)
e
l
n
 SYEN  Synchronization End  PLC to indicate that its send buffer is empty and to
t
U
close synchronization mode
r
s
a
e
 LIFE  Life Telegram  EWM and PLC to check the connection
P
S A P
S A P
 STAR  Status Request  EWM to aks for the current availability of an equipment
 STAT  Status Message  PLC to indicate that an equipment is temporarily not
P a
available resp. available again
s e
 WT  Warehouse Task  EWM to give an order to the PLC to move a HU
r
U
t
n
 WTCO  Warehouse Task Confirmation  PLC to indicate that a task has been executed
l
e
a
r
n
 LOCL  Location Left  PLC to indicate that a HU has left a location

r
O
e
n
t
 WTCR  Cancellation Request  EWM to cancel a warehouse task
l
n
y
I
 WTCC  Cancellation Response  PLC to respond to a cancellation request from EWM
 SCAN  Scanner Message  PLC to announce a HU at a location
Communication Protocol
Synchronisation after Restart
I
l y
n
EWM (Client) Channel PLC (Server)
t
O n
e
r
n
Sync Request
r
a
The PLC acts as server
e
l
n
EWM connects to the PLC

t
U
EWM initates the communication process
r
s
by sending a synchronization request Sync Begin
a
e
P
S A P
S A P
... buffered telegrams ...
P a
s e
EWM accepts all outstanding messages
r
U
t
from the PLC before it starts to send
n
new tasks
l
e
a
Sync End
r
n
r
O
e
n
t
l
Next Task
n
y
I
(Acknowledgment telegrams are not shown)

Message Buffering
I
l y
n
EWM EWM
t
O n
Application Channel
e
PLC
r
n
r
a
e
l
n
Tele 1
t
U
r
s
a
e
P
Tele 2 Tele 1
S A P
S A P
Buffer
P a
s e
Buffer
r
U
t
Ack 1
n
Table /SCWM/MFSDELAY
l
e
a
r
n
r
O
e
n
t
l
n
y
Tele 2
I
Send and Receive at the Same Time
I
l y
n
EWM PLC
t
Channel Channel
O n
e
r
n
r
a
e
l
Tele 1
n
Tele 1
t
U
r
s
a
e
P
S A P
S A P
Both sides accept

a new telegram
P a
while waiting for an
s e
acknowledgement Ack 1 Ack 1
r
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
Communiaction Protocol
Life Check & Channel Reconnect
I
EWM PLC
l y
n
t
O n
e
Tele 1
r
n
r
a
e
l
Tele 2
n
Telegram Repetition Process (Batch Job):

t
U
• Checks for outstanding ack. telegrams
r
s
Tele 2
a
• Repeats telegrams n time with the same
e
?
P
sequence number
S A P
• Then closes and reopens the channel
S A P
Tele 2
• Repeats the same telegram again (same
sequence number)
Close Event
P a
• Sends LIFE check telegrams on timeout
s e
• Is responsible for all channels within warehouse
r
number
U
Tele 2 (!)
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
I
l y
n
1. Telegram structures
t
O n
e
2. Interface Types
r
n
r
a
3. PLCs and communication channels
e
l
n
t
U
4. PLC and EWM exceptions
r
s
a
e
P
S A P
S A P
P a
s e
r
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
Telegram Structure
Header and Body
I
All telegram structures must include a header structure (as .INCLUDE)
l y
n
 Used for the communication protocol
t
O n
e
 Identical for all telegrams of a single PLC
r
n
r
a
e
l
Header Structure must include the fields  Any fixed sequence of these fields within the header
n
structure is allowed.
t
– Sequence number
U
r
Indicates to the receiver if the telegram has been received before
s
 If one of these fields is missing in a given protocol
a
e
– Handshake flag BAdIs have to be implemented (manipulation of
P
Data or acknowledgement telegram telegrams for sending / receiving)
S A P
S A P
– Communication error
To be set by the receiver in the acknowledgement telegram. Should be blank or zero.
– Telegram type
P a
Defines the scope of the telegram and the structure of the rest of the telegram
s e
r
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
Define Telegram Structures

Based on /SCWM/S_MFS_TELETOTAL
I
l y
n
EWM
t
O n
e
Structure /SCWM/S_MFS_TELETOTAL
r
n
SEQU_NO
r
a
TELETYPE
e
l
HUIDENT
n
HUTYP
...
t
U
RSRC
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s
CP
a
/SCWM/S_MFS_TELETOTAL CS
e
 Function
P
WT
Modul X
S A P
Z_TELE: ...
S A P
SOURCE SEQU_NO
Field Mapping by Field Name DEST TELETYPE
... HUIDENT Z_TELE
LENGTH SOURCE
WIDTH
P a
DEST
s e
... MFS_ERROR
MFS_ERROR
r
U
t
n
l
e
a
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String max 255 Byte
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alphanumeric characters
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O
only!
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n
t
l
n
y
PLC SEQU_NO
Z_TELE
I
TELETYPE
HUIDENT
PLC Event SOURCE
DEST
MFS_ERROR
I
l y
n
t
O n
e
2. Interface Types
r
n
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P
S A P
S A P
P a
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t
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l
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a
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O
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t
l
n
y
I
Two Ways to Assign Structures to PLCs
I
l y
n
t
O n
e
r
Interface Type PLC
n
r
a
5.1 and higher
e
l
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t
U
Telegram
r
PLC
s
Structures
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e
P
5.0
S A P
S A P
P a
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t
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l
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a
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y
I
Define Interface Types
I
Interface Types combine a set of properties and are assigned to PLCs
l y
n
t
O n
e
r
n
r
a
Telegram Structures Telegram Structures
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l
n
t
U
Telegram Types Telegram Types
r
s
a
e
Error Codes Error Codes
P
S A P
S A P
Interface Type Interface Type
P a
s e
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U
t
n
l
e
a
r
n
r
O
e
PLC
n
CONSYS1 CRANE01 CRANE02 CRANE03
t
l
n
y
I
CP CP
Telegram Types
I
PLC
l y
n
t
O n
e
r
n
r
a
e
l
n
t
U
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s
a
e
P
S A P
S A P
Note: Telegram Types are just
P a
identifiers for telegram categories.
s e
They can be freely defined with the
r
U
PLC vendor (max. 4 char).
t
n
l
e
a
r
n
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O
e
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t
l
n
y
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I
l y
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t
O n
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2. Interface Types
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n
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P
S A P
S A P
P a
s e
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U
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e
a
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n
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O
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t
l
n
y
I
Define PLC and Assign Header Structure
The header structure is used for the
I
PLC
l y
n
communication protocol and to indicate
t
O n
scope and structure of the telegram to the
e
receiver.
r
n
r
a
e
l
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s
a
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P
S A P
S A P
P a
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a
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I
© SAP 2010 / Page 18 I n t e r n a l U s e S A P P a r t n e r O n l y

PLC Customizing
I
l y
Every external system, which should be
n
t
connected using the MFS telegram interface,
O n
e
Recommendations
r
must be defined as a PLC.
n
r
a
 Put away – WPT:
e
l
Rel. 5.0 only
n
 Don’t set here, set WPT on CP level at ID-Point

t
U
r
 Process Type Fault:
s
a
e
Is used to post an HU to a new location in case of flow
P
error.
S A P
 Use a WPT allowing “confirm immediately”.
S A P
 Exception Code MFS:

Is used to control the reaction in case of flow error.
 Use an exception code creating an alert and triggering
P a
s e
internal process code CHBD.
r
 will post the HU to the new location and make this
U
t
exception visible to the supervisor
n
l
 Mapping:
e
a
Controls if the mapping table is used to map EWM
r
n
storage bin names to PLC addresses.

r
O
 use if the PLC cannot deal with EWM bin names.
e
n
t
 Identification:
l
n
y
Is set as sender in outgoing telegrams and expected in
I
incoming telegrams, if customizing flag “check telegram”

is set in communication channel customizing.
Communication Channel Customizing
I
To every PLC at least one communication channel must be defined
l y
n
t
O n
e
Recommendations Communication Channel
r
n
r
 Don’t use fill characters
a
e
 may not work in every situation
l
n
 Set handshake identifiers

t
U
 otherwise BAdI must be implemented
r
s
a
Use handshake mode “send complete telegram”
e

P
 eases programming on PLC side
S A P
S A P
 Use life telegrams

 connection loss will be detected automatically
 Activate Get Sequence Numbers for life telegrams
P a
 no exceptional coding needed
s e
 Use an end character
r
U
 will ease reading the log
t
n
 Use fixed telegram length
l
e
 eases programming on PLC side
a
r
n
 Use an exception code which is configured to close and reopen the channel in
r
O
case of connection loss (int. process code “REST”)
e
n
 otherwise connection won’t be reestablished
t
l
n
 Use synchronization
y
 will force MFS to immediately send a telegram if a channel is started
I
I
l y
n
t
O n
e
2. Interface Types
r
n
r
a
e
l
n
t
U
r
s
a
e
P
S A P
S A P
P a
s e
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U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
Standard Exceptions and PLC Error Codes
I
l y
n
t
O n
e
r
n
r
a
e
l
n
t
U
r
s
a
e
P
S A P
From PLC
S A P
To PLC
P a
s e
Match EWM Exceptions to PLC Errors:
r
What code is to be set in a telegram to the PLC in case of Error ...?
U
t
n
l
e
Match PLC Errors to EWM Exceptions:
a
What does it mean if the PLC sends error „90“?
r
n
r
O
e
n
t
l
n
y
I
Agenda
I
l y
n
t
O n
e
r
n
r
a
e
l
n
t
U
2. Maintain PLC master data
r
s
a
e
P
S A P
4. Setup SAP PCo
S A P
P a
s e
r
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
Maintain Master Data and RFC
I
l y
n
1. Create RFC destination
t
O n
e
2. Maintain PLC: Assign RFC destination
r
n
r
a
3. Maintain communication channel: Assign IP address and port
e
l
n
t
U
r
s
a
e
P
S A P
S A P
P a
s e
r
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
PLC Interface Settings
I
l y
n
IMG Master Data
t
O n
e
r
n
r
a
e
l
n
PLC TeleStructHeader PLC CommLayer

t
U
Except. Deviation RFC Destination
r
s
a
Tele Logging
e
Activate Mapping
P
Interface Type TeleType
S A P
S A P
Fault Process Type TeleStruct

Bin Mapping
Sender Ident EWM Tele Err Codes
P a
s e
r
U
t
n
l
Channel Sequ No range Channel IP / Port
e
a
r
Timeouts
n
r
O
Telegr. Length
e
n
Handshake
t
l
n
y
Except. Restart
I
Synchronisation
Std. ErrorCode
...
Create RFC Destination
I
l y
n
EWM
t
O n
e
r
n
r
a
e
l
n
t
U
r
s
a
e
P
S A P
S A P
SM59
P a
RFC Destination ZTR_PLC_GATEWAY2
s e
Program ID TR_PLC_GATEWAY2
r
U
t
n
l
e
a
r
n
RFC-Adapter
r
O
e
n
t
l
n
y
I
PLC
Maintain PLC
Assign Communication Layer and RFC Destination
I
l y
n
EWM
t
O n
e
r
n
r
a
e
l
n
t
U
r
s
a
e
P
S A P
S A P
SM59
P a
s e
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U
t
n
l
e
a
r
n
RFC-Adapter
r
O
e
n
t
l
n
y
I
PLC
Maintain Communication Channel

Assign IP Address and Port
I
l y
n
EWM
t
O n
e
r
n
r
a
e
l
n
t
U
r
s
a
e
P
S A P
S A P
SM59
P a
s e
r
U
t
n
l
e
a
r
n
RFC-Adapter
r
O
e
n
t
l
n
y
I
Socket Server
PLC
Connect RFC Adapter
I
l y
n
EWM
t
O n
e
r
n
r
a
e
l
n
t
U
r
FM /SCWM/MFS_RECEIVE2
s
a
e
P
S A P
S A P
SM59
P a
s e
r
U
t
n
l
e
a
r
RFC Handler
n
The adapter registers the program ID in SAP Logon

RFC-Adapter
r
O
SAP and calls /SCWM/MFS_RECEIVE2 Program ID
e
n
Socket Client
t
l
n
y
I
Socket Server
PLC
Runtime
I
l y
n
EWM I love you, it
t
CONSYS1
works..!
O n
e
r
Me too
n
r
a
e
l
n
t
U
r
/SCWM/MFS_RECEIVE2
s
a
e
P
S A P
S A P
SM59
P a
s e
r
U
t
n
l
e
a
r
RFC Handler
n
RFC-Adapter
r
O
e
Socket Client
n
t
l
n
y
I
... words
Socket Server
..
PLC I love you,

Me too
CONSYS1
Agenda
I
l y
n
t
O n
e
r
n
r
a
e
l
n
t
U
2. Maintain PLC Master Data
r
s
a
e
P
S A P
4. Setup SAP PCo
S A P
P a
s e
r
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
Internal Test with

/SCWM/MFS_SIM_RECEIVE
I
l y
n
I love you,
EWM CONSYS1 it
t
works..!
O n
e
r
Me too
n
r
a
e
l
n
t
U
r
s
... confirming
a
everything
e
P
S A P
S A P
FM /SCWM/MFS_SIM_RECEIVE
Me too
P a
s e
RFC Destination
r
U
t
n
l
e
a
r
RFC Handler
n
RFC-Adapter
r
O
e
n
Socket Client
t
l
n
y
I
Socket Server
PLC
Internal Test with

/SCWM/MFS_SIM_RECEIVE
I
l y
n
The internal function module /SCWM/MFS_SIM_RECEIVE includes:
t
O n
e
 Telegram Acknowledgement
r
n
r
 Synchronization
a
e
l
n
 Status Request
t
U
r
 Warehouse Task Confirmation
s
a
e

P
Warehouse Task Cancellation
S A P
 Customizing is used
S A P
It does not include:
P a
□ Scanner Messages
s e
r
□ Location left telegram
U
t
n
□ Forced Errors (equipment fault, outline error, bin occupied, ...)
l
e
a
r
n
r
O
e
n
t
l
n
y
I
Agenda
I
l y
n
t
O n
e
r
n
r
a
e
l
n
t
U
r
s
a
e
P
S A P
4. Setup SAP PCo
S A P
P a
s e
r
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
PCo in General
I
l y
n
 Is free of charge if the customer has licensed EWM
t
O n
e
r
 Can be downloaded from service market place (software distribution center)
n
r
a
e
l
 PCo 2.1 currently in ramp-up (planned end: June 2010)
n
t
U
r
s
a
 Product Information available in the service market place:
e
P
http://www.sap.com/solutions/manufacturing/index.epx
S A P
S A P
 Requires Microsoft .NET Framework 3.5 Service Pack 1.
P a
s e
r
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
Installing PCo
I
PCo provides different shop floor communication techniques.
l y
n
For EWM we need Socket Agent and RFC Destination only.
t
O n
e
r
n
r
a
e
l
n
t
U
r
s
a
e
P
S A P
S A P
P a
s e
r
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
SAP Plant Connectivity
I
l y
n
EWM SYES
t
LIFE
O n
e
SYBE
r
SYEN
n
LIFE
r
a
e
l
n
t
U
r
s
a
e
P
S A P
S A P
SM59
P a
s e
r
U
t
n
l
e
a
„Destination Channel“
r
„Notification“
n
„Agent
r
SAP PCo 2.0, 2.1
O
Instance“
e
„Source Channel“
n
t
l
n
y
I
Socket Server
Java PLC Emulation SYES

SYBE
SYEN
LIFE
LIFE
Configuring PCo Source System
I
l y
PCo
n
t
O n
Source System Agent Instance Destination System
e
PLC Socket Service RFC
SAP
r
n
r
a
e
l
n
t
U
r
s
a
e
P
S A P
S A P
Create
source
uncheck
P a
system
s e
r
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
Configuring PCo Destination System
I
l y
PCo
n
t
O n
e
PLC Socket Service RFC
SAP
r
n
r
a
e
l
n
t
U
Activate
r
s
reliability
a
e
Create
P
S A P
destination
S A P
system Program ID
maintained in
sm59
P a
s e
r
SAP App. server
U
t
& gateway
n
l
e
service
a
r
n
r
O
e
n
t
SAP credentials
l
n
y
I
Test connection
Configuring PCo Agent Instance
I
l y
n
PCo
t
O n
e
PLC SAP
r
Socket Service RFC
n
r
a
e
l
n
t
U
r
s
a
e
P
S A P
S A P
Create agent
P a
instance
s e
(Windows
r
U
service)
t
n
l
e
a
r
n
r
O
Option: Start
e
n
automatically
t
l
n
y
I
uncheck
I
l y
n
PCo
t
O n
e
PLC SAP
r
Socket Service RFC
n
r
a
e
l
n
t
U
r
s
a
e
P
S A P
S A P
Enable
notification
trigger
P a
s e
Add
r
U
t
notification
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
I
l y
n
PCo
t
O n
e
PLC SAP
r
Socket Service RFC
n
r
a
e
l
n
t
U
r
s
a
e
P
S A P
S A P
Add notification
destination
(RFC)
P a
s e
r
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
Agenda
I
l y
n
t
O n
e
r
n
r
a
e
l
n
t
U
r
s
a
e
P
S A P
4. Setup SAP PCo
S A P
P a
s e
r
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
PLC Emulation Tool
I
l y
n
Is installed locally on a PC
t
O n
e
r
Requires Java runtime environment 6 (jre6)
n
r
a
e
l
Needs to be configured according to the MFS project in local .csv files
n
t
U
 Communication channels
r
s
a
e
 Telegram types
P
S A P
 Telegram structure header
S A P
 Telegram structure body
P a
s e
r
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
Emulation reads its settings from
I
local csv files
Emulation Settings - Ports & Telegram Types
I
Maintain socket ports Maintain telegram type IDs
l y
n
t
O n
e
r
n
r
a
e
l
n
t
U
r
s
a
e
P
S A P
S A P
Maintain telegram header structure
P a
s e
r
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
Maintain telegram body structure

Start PLC Emulation
I
Double click “start.bat”
l y
n
t
O n
e
r
n
r
a
e
l
n
t
U
r
s
a
e
P
S A P
S A P
P a
s e
Choose project and version:
r
U
t
n
l
e
Activate telegram logging to console:
a
r
n
r
O
e
n
t
l
n
y
I
Start PLC Emulation
I
l y
n
Activate logging monitors
t
Start Emulation (response times, number of
O n
e
telegrams/s)
r
n
r
a
e
l
n
t
U
r
s
a
e
P
S A P
S A P
P a
s e
r
U
t
n
l
e
a
r
n
r
O
e
n
Set an HU to ID point
t
l
conveyor (right click)
n
y
I
I
l y
n
t
O n
e
r
n
r
a
e
l
n
t
U
r
s
a
e
P
S A P
S A P
SAP EWM 210_3
P a
s e
r
U
t
n
l
e
a
r
n
r
O
e
Setup Material Flow
n
t
l
n
y
I

Curriculum
I
l y
n
t
O n
e
r
n
r
a
e
l
n

t
U
r
s
a
e
EWM210 3h
P
S A P
(MFS) in EWM
S A P
EWM220 2h
P a
RadioFrequency
s e
Framework (RF)
in EWM
r
U
t
Clasroom training
n
EWM230 2h
l
e
a
ITSMobile
r
& RadioFrequency
n
in EWM
r
O
e
n
t
l
n
y
I
Agenda
Setup Material Flow
I
l y
n
t
O n
e
r
n
r
a
e
1. Warehouse Layout
l
n
t
U
2. Routing
r
s
a
3. Task Creation
e
P
S A P
4. Task Communication
S A P
5. PLC Event Processing
P a
6. Capacity Management
s e
r
7. Exceptions
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
Warehouse Layout
Storage Types and Roles
I
l y
Define a separate storage type for final and for intermediate
n
storage locations and assign appropriate role.
t
O n
 Warehouse Monitor separates MFS relevant WTs and HUs.
e
CR3
r
n
CR1
TRR01
r
a
Final storage locations (aisles): CR2
e
l
• Storage type role „J“: Automatic Warehouse
n
t
U
r
s
a
e
P
CP12 CP13 CP16 CP17 CP20 CP21
S A P
S A P
P a
s e
Intermediate storage locations (conveyor system): TCAR

• Storage type role „H“: Automatic Storage Retrieval
r
U
CP01 CP10
t
CP02 CP03 CP05 CP07
(IP) (IP)
n
l
e
a
r
CP08
n
CP00 CP04 CP06

(PP)
r
O
e
CP09
n
t
l
n
y
I
“E”: Work Center Clearing
Warehouse Layout
Storage Bins – Communication Points - Resources
I
l y
n
Resource
t
• MFS controls HUs
O n
e
CR3
r
• HUs can be posted to storage bins or
n
CR1
TRR01
resources
r
a
CR2
 Every MFS relevant conveyor
e
l
n
location has to be modeled as Storage Bin

t
U
storage bin and Communication
r
s
a
Point
e
P
• Communication Points are linked to CP12 CP13 CP16 CP17 CP20 CP21
S A P
S A P
storage bins for

• MFS capacity (number of HUs) Communication CP11 CP14 CP15 CP18 CP19 CP22
P a
• Physical State Point and
s e
TCAR
Storage Bin
r
• Telegram Processing
U
CP01 CP10
t
CP02 CP03 CP05 CP07
(IP) (IP)
n
• other MFS relevant settings
l
e
a
r
CP08
n
CP00 CP04 CP06

(PP)
r
O
e
CP09
n
t
l
n
y
Storage Bin
I
Clearing
Resource
(optional)
Warehouse Layout
Communication Points
I
l y
n
t
O n
e
r
n
HU exception will
r
be cleared
a
Allows to control
e
l
the function
n
module to deal
t
U
with a PLC Use for ID point
r
s
telegram from this only
a
e
CP
P
S A P
Indicates ID Point
S A P
resp. conveyor
end point (normal Stop layout-
or NIO) oriented storage
control
P a
Switch off CP
s e
FIFO (see next
r
slide) What to do in
U
t
case of
n
bottleneck
Number of HUs
l
e
(STAY, NSND)
a
allowed at CP
r
n
and mode to
calculate them Next CP
r
O
direction NIO
e
n
t
l
n
y
Deactivate
I
capacity /
availability check
direction NIO
RF WT to clearing area at the end of
NIO conveyor
Warehouse Layout
I
l y
n
t
Event: Scanner message for HU 2
O n
e
r
n
forbidden
r
a
e
l
CP without scanner flag (CP FIFO): 3 2 1
n
WT for HU 2 will only be sent to the PLC after

t
U
WT for HU 1 has been sent
r
s
CP01
a
e
No scanner flag
P
S A P
S A P
P a
s e
r
allowed
U
t
CP with scanner flag activated (no CP FIFO):
n
3 2 1
l
Logical HU sequence will not be considered
e
a
r
n
CP01
r
O
Scanner flag
e
n
t
l
n
y
I
Warehouse Layout
I
l y
n
t
O n
e
r
n
r
a
Customizing Application
e
l
n
t
U
r
s
a
e
CP CP Storage Bin
P
S A P
S A P
Assign
• storage bin
P a
s e
• pack material to scanners (for “UFOs”)
r
U
t
n
l
e
a
r
n
r
O
generated Manual Assignment
e
n
t
l
n
y
I
Warehouse Layout
Resources
I
l y
n
t
Customizing
O n
Application
e
r
n
r
a
Use type
e
l
Resource Type Resource
n
t
U
r
s
a
e
P
Create manually
S A P
S A P
P a
s e
r
U
t
n
l
e
a
r
Above all try to always Capacity:
n
send a put away task Number of tasks

r
O
after a retrieval task and that are optimized
e
n
vice versa by the PLC itself
t
l
n
y
I
Task and task

confirmation
telegram sequence
One queue Default destination in

per resource case of error “bin
occupied”
Warehouse Layout
Conveyor Segments
I
l y
n
t
• Segments represent conveyors between CPs
O n
e
CR3
r
• Segments are assigned to intermediate destinations
n
CR1
TRR01
in the layout-oriented storage control (customizing)
r
a
CR2
e
l
n
• Segments are checked to be available regarding

t
U
capacity and equipment fault during task execution
r
s
a
e
• Segment can be blocked by
P
Segment CP12 CP13 CP16 CP17 CP20 CP21
S A P
• PLC state telegram
S A P
• Warehouse Monitor
P a
Segment Group
s e
TCAR
r
U
CP01 CP10
t
CP02 CP03 CP05 CP07
• Segment groups combine a number of segments. (IP) (IP)
n
Advantage: A complete area can be set out of order
l
e
a
with a single PLC telegram
r
CP08
n
CP00 CP04 CP06

(PP)
r
O
e
CP09
n
t
l
• Recommendation:
n
y
I
Try to model the layout in MFS with help of CPs first.

Use segments if CPs aren‟t sufficient. Clearing
Segment capacity calculation: Number of WTs sent to the PLC and not yet confirmed
Agenda
Setup Material Flow
I
l y
n
t
O n
e
r
n
r
a
e
1. Warehouse Layout
l
n
t
U
2. Routing
r
s
a
3. Task Creation
e
P
S A P
S A P
P a
s e
r
7. Exceptions
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
Routing
Storage Control Groups
I
l y
n
Storage control groups RACK 1
t
O n
• Are a means to control layout oriented routing
e
r
• Are property of storage bins.
n
r
BIN
a
e
l
BIN
n
BIN
t
U
r
s
a
e
P
S A P
Storage Control Group
S A P
RCK1
BIN
BIN CP01 CP02
P a
s e
BIN
r
BIN RACK 2
U
t
Storage Control Group Storage Control Group
n
CP01 CP02
l
e
a
BIN
r
n
BIN
r
O
That means: 3 names for the same physical
e
BIN
n
conveyor location!
t
Storage Control Group
l
n
GR01 (CP, Storage Control Group, storage bin.
y
I
Storage Control Group is 4 bytes only.)

Goods Reception Storage Control Group
RCK2
Routing
Standard Routing for Slow* Moving HU Types
I
l y
n
t
O n
e
WT1
HU
inactive
r
Step 1
n
r
a
WT2
e
active
l
n
t
U
r
Bin 1 Bin 2 Bin n Final Bin
s
a
e
P
S A P
WT1
HU
S A P
inactive
Step n
WT3
P a
active
s e
r
U
t
n
l
e
a
WT1
r
HU
active
n
Final Step
r
O
e
n
t
l
n
y
I
* Sub second response time requirement

Routing
Fast* Routing Option (NL Development)
I
Product WT
l y
n
Product Requirement inactive active
t
HU Final Bin
O n
Product WT from HU to final bin
e
Activity Area1
r
n
r
At Scanner:
a
e
1. Receive sort request Scanner 1 Scanner 3
l
Scanner 2
n
2. Send sort instruction  “LEFT”  “CHUTE1”  “LEFT”

t
U
3. Evaluate sort report HU WT  CONV1 (confirmed) HU WT  WA_AA1 (confirmed)
r
HU WT  LOOP1 (confirmed)
s
(post sort result)
a
e
P
S A P
HU posted to storage GR Bin Bin Work Station
S A P
bin representing an area “Conv1” “LOOP1” “WS_AA1”
P a
s e
• Routing decision taken from a Z-Table Z Routing Table (Customizing)
r
Decision Logistical PLC Data After
• Based on logistical destinations
U
t
Point Destination Destination Sorting
n
• Logistical destinations determined by CP specific
l
Scanner 1 REJECT RIGHT CLEARING
e
Z-MFS action FM triggered by PLC telegrams,
a
r
considering Scanner1 ELSE LEFT CONV1
n
r
O
• final destination (inactive WT) Scanner2 Activity Area 1 CHUTE1 LOOP1
e
n
• HU exceptions (weight, differences, user
t
Scanner2 Activity Area 2 CHUTE2 LOOP2
l
exception, …)
n
y
Scanner2 ELSE CHUTE3
I
• HU posting
Scanner3 Activity Area 1 LEFT WS_AA1
• after sorting
• May be not necessary for every step Scanner3 ELSE STRAIGHT
* < 0.5sec response time requirement, high volume

Routing
Standard Routing in Case of Exceptions
I
l y
n
t
O n
e
r
HU marked with exception code
n
r
a
e
l
n
t
U
MHUX
r
s
a
e
P
S A P
CP01 NIO: CP03 NIO: CP04 CP03
S A P
P a
s e
r
U
t
n
l
e
a
r
n
NIO CP04
r
O
e
n
t
l
n
y
I
Layout-oriented storage control is not taken into account
Routing
Identification Point
I
Layout Oriented Storage Control with ID Point
l y
n
t
O n
e
9010
r
CR3
0280
n
CR1
r
TRR01
a
CR2
e
HU 1
l
n
t
U
r
s
a
e
P
S A P
S A P
TCAR
CP02 CP01 CP10

CP03 CP05 CP07
(IP) (IP)
P a
s e
CP00 CP04 CP08

CP06
(PP)
r
CP09
U
t
n
l
e
Destination of put away task is changed to the storage bin specified in layout
a
r
oriented storage control
n
r
O
e
n
t
l
n
y
I
Routing
Pick Point – Goods to Man
I
l y
CR3
n
Full pallet stock removal: No pick point CR1
t
TRR01
O n
CR2
e
r
n
r
a
e
l
n
t
U
r
s
a
TCAR
e
P
CP01 CP10
CP02 CP03 CP05 CP07
(IP) (IP)
S A P
S A P
CP00 CP04 CP08

CP06
(PP)
CP09
P a
s e
r
U
t
n
l
e
a
r
n
Partial stock removal:

r
O
e
n
t
l
n
y
Pick Point activated
I
Pick Point
Routing
I
l y
Outbound Delivery CR3
n
CR1
t
 Pos 10: 1000 kg Prod A 65 TRR01
O n
CR2
e
 Pos 20: 2 Pc Prod B
r
66
n
r
a
e

Stock
l
n
 HU 65: 1000 kg Prod A  full movement

t
U
HU 66: 371 Pc Prod B  pick point
r
s
a
TCAR
e
P
CP01 CP10
CP02 CP03 CP05 CP07
(IP) (IP)
S A P
EWM creates 2 WTs for a stock removal requirement
S A P
CP00 CP04 CP08

CP06
 Product-WT and (PP)
CP09
 HU-WT.
P a
If the HU-WT can not be executed directly a 2nd HU-WT is created.
s e
1000 kg
r
2 Pc
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
9020 GI-Zone
y
Legend
I
Inactive Active
Product WT
HU WT
Routing
I
l y
CR3
n
CR1
t
TRR01
O n
CR2
e
The source location of all WTs is adjusted step by step
r
n
r
a
e
CP12
65
CP13 CP16 CP17 CP20
66
CP21
l
n
t
U
r
s
a
TCAR
e
P
CP01 CP10
CP02 CP03 CP05 CP07
(IP) (IP)
S A P
S A P
CP00 CP04 CP08

CP06
(PP)
CP09
P a
s e
r
1000 kg
U
t
2 Pc
n
l
e
a
r
n
r
O
e
n
t
l
n
9020 GI-Zone
y
Legend
I
Inactive Active
Product WT
HU WT
Routing
I
l y
CR3
n
CR1
t
TRR01
O n
CR2
e
r
n
r
a
e
l
n
t
U
CP11
65
CP14 CP15 CP18 CP19
66
CP22
r
s
a
TCAR
e
P
CP01 CP10
CP02 CP03 CP05 CP07
(IP) (IP)
S A P
S A P
CP00 CP04 CP08

CP06
(PP)
CP09
P a
s e
r
1000 kg
U
t
2 Pc
n
l
e
a
r
n
r
O
e
n
t
l
n
9020 GI-Zone
y
Legend
I
Inactive Active
Product WT
HU WT
Routing
I
l y
CR3
n
CR1
t
TRR01
O n
CR2
e
r
n
r
a
e
l
n
t
U
r
s
a
TCAR
e
P
CP02
CP01
(IP)
CP03
65 66
CP05 CP07
CP10
(IP)
S A P
S A P
CP00 CP04 CP08

CP06
(PP)
CP09
P a
s e
r
1000 kg
U
t
2 Pc
n
l
e
a
r
n
r
O
e
n
t
l
n
9020 GI-Zone
y
Legend
I
Inactive Active
Product WT
HU WT

Routing
I
l y
CR3
n
CR1
t
TRR01
O n
CR2
e
r
n
r
a
The inactive WT gets active if there is no further
e
l
n
intermediate destination
t
U
r
s
a
TCAR
e
P
CP01 CP10
CP02 CP03 CP05 CP07
(IP) (IP)
S A P
S A P
CP08
CP00 CP04
65
CP06
66
(PP)
CP09
P a
s e
1000 kg
r
U
t
n
l
2 Pc
e
a
r
n
r
O
e
n
t
l
n
9020 GI-Zone
y
Legend
I
Inactive Active
Product WT
HU WT
Routing
I
Work Center KPL1
l y
CR3
n
CR1
t
TRR01
O n
CR2
e
r
A)
n
r
Create new customer HU (101) at CP09
a
e
l
n
t
U
B) CP11 CP14 CP15 CP18 CP19 CP22
r
s
a
Drag quantity from storage HU 66 to customer HU 101 TCAR
e
P
CP01 CP10
confirms WT 78286 CP02
(IP)
CP03 CP05 CP07
(IP)
S A P
S A P
CP00 CP04 CP06

66
CP08
(PP)
101 CP09
P a
s e
r
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
Routing
I
Work Center KPL1
l y
CR3
n
CR1
t
TRR01
O n
C) CR2
e
Close customer HU 101:
r
n
Two new WTs for moving it to the GI-Zone are created.
r
a
e
l
n
t
U
r
s
a
TCAR
e
P
CP01 CP10
CP02 CP03 CP05 CP07
(IP) (IP)
S A P
S A P
CP00 CP04 CP06

66
CP08
(PP)
101 CP09
P a
s e
r
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
9020 GI-Zone
y
Legend
I
Inactive Active
Product WT
HU WT
Routing
I
l y
CR3
n
CR1
t
TRR01
O n
CR2
e
In this example the customer HU is moved to the GI-
r
Zone by use of layout-oriented storage control.
n
r
a
e
l
n
t
U
r
s
a
TCAR
e
P
CP02
CP01
(IP)
CP03 CP05 CP07
101
CP10
(IP)
S A P
S A P
CP00 CP04 CP06

66
CP08
(PP)
CP09
P a
s e
r
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
9020 GI-Zone
y
Legend
I
Inactive Active
Product WT
HU WT
Routing
I
Work Center KPL1
l y
CR3
n
CR1
t
TRR01
O n
D) Close the storage HU 66: A new WT to 0280 is created. CR2
e
r
n
r
a
e
l
n
t
U
r
s
a
TCAR
e
P
CP01
CP02
(IP)
CP03
101
CP05 CP07
CP10
(IP)
S A P
S A P
CP00 CP04 CP06

66
CP08
(PP)
CP09
P a
s e
r
U
t
n
l
e
WT destination is changed to CP10 (ID point for CP08) based on customizing:
a
r
n
r
O
e
n
t
l
n
y
Legend
9020 GI-Zone
I
Inactive Active
Product WT 65
HU WT

Routing
I
l y
CR3
n
CR1
t
TRR01
O n
CR2
In this example the storage HU is moved back to the
e
r
high bay storage by use of a second ID point at CP10
n
and the layout-oriented storage control.
r
a
e
l
n
t
U
r
s
a
TCAR
e
P
CP01 CP10
CP02
(IP)
CP03 CP05 CP07
66
(IP)
S A P
S A P
CP00 CP04 CP08

101
CP06
(PP)
CP09
P a
s e
r
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
9020 GI-Zone
y
Legend
I
Inactive Active
65
Product WT
HU WT
Agenda
Setup Material Flow
I
l y
n
t
O n
e
r
n
r
a
e
1. Warehouse Layout
l
n
t
U
2. Routing
r
s
a
3. Task Creation
e
P
S A P
S A P
P a
s e
r
7. Exceptions
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I

Task Creation
Warehouse Tasks and Warehouse Orders
I
l y
n
t
Manual Execution (RF) Execution by a PLC
O n
e
r
n
r
a
Warehouse Task 1 Warehouse Task 2 Warehouse Task 1 Warehouse Task 2
e
l
n
t
U
1:1
r
s
n:1
a
e
Warehouse Order 1 Warehouse Order 2
P
Warehouse Order 1
S A P
S A P
Queue 1 Queue 1
P a
s e
1:1
n:m
r
U
t
n
l
Resource 1 Resource 2
e
Resource
a
r
n
n:1
r
O
e
n
PLC
t
l
n
y
I
 1 WO may contain several WTs  1 WO contains just 1 WT

 1 WO is executed by 1 resource  1 WO is executed by 1 resource or a PLC directly
 1 resource may execute WOs from several queues  1 resource executes WOs from just 1 queue
 Several resources may execute several queues  1 PLC may execute several queues via different resources
and another one directly
Task Creation
WO Creation and Queue Determination
I
l y
n
t
O n
e
r
CP CP
n
r
a
e
Storage Bin Storage Bin
l
n
t
U
r
s
a
e
P
S A P
S A P
Warehouse Task
P a
s e
Queue Determination Criteria Warehouse Order Creation Rule
r
U
t
n
l
e
Queue Warehouse Order
a
r
n
r
O
e
is communicated to executes
n
t
l
n
y
PLC optional: Resource
I
Task Creation
WO Creation
I
l y
n
t
From Storage Bin To Storage Bin
O n
e
r
n
r
a
e
l
n
t
U
Warehouse Task Warehouse Process Type Activity MFSI
r
s
a
To Activity
e
Area
P
From Activity
Area
S A P
S A P
Sort Sequence Sort Sequence

Order Creation Rule Act. Area / Activity
Act. Area / Activity
P a
s e
r
U
t
combines tasks
n
Queue Warehouse Order
l
MFS 1:1
e
a
r
n
r
O
is communicated to executes
e
n
t
l
PLC Resource
n
y
I
Legend
for technical reason only
Task Creation
WO Creation
I
l y
n
t
O n
e
Define a limit with 1 item / WO WO Creation Rule for PLCs
r
n
r
a
e
l
n
t
U
r
s
a
e
P
S A P
S A P
P a
s e
r
Apply PLC WOCR based on activity area and activity
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
Task Creation
Queue Determination
I
l y
n
Source Storage Bin Destination Storage Bin
t
O n
e
r
n
Warehouse Task
r
a
e
l
n
t
U
r
s
a
Warehouse Process
e
Bin Access Type Activity MFSI
Type
P
S A P
S A P
P a
from to
s e
r
Activity Area Queue Determination Criteria Activity Area
U
t
n
l
e
a
r
n
combines tasks
Queue Warehouese Order
r
O
MFS 1:1
e
n
t
l
n
is communicated to
y
executes
I
PLC Resource
Task Creation
Queue Determination
I
l y
n
Define bin access types per PLC
t
O n
e
r
n
r
a
e
l
Carefully consider queue access sequence
n
t
U
r
s
a
e
P
Determine queue by bin access type and activity
S A P
S A P
P a
s e
r
U
t
n
l
e
a
r
n
r
O
Assign operation environment to queue
e
n
t
l
n
y
I
Agenda
Setup Material Flow
I
l y
n
t
O n
e
r
n
r
a
e
1. Warehouse Layout
l
n
t
U
2. Routing
r
s
a
3. Task Creation
e
P
S A P
S A P
P a
s e
r
7. Exceptions
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
Task Communication
Material Flow Related Telegram Categories
Usage
I
l y
n
t
O n
e
 SYES  Synchonization Setup  EWM to initiate connection to PLC
r
n
r
 SYBE  Synchronization Start  PLC to start synchronization mode (answer to SYES)
a
e
l
n
 SYEN  Synchronization End  PLC to indicate that its send buffer is empty and to
t
U
close synchronization mode
r
s
a
e
 LIFE  Life Telegram  EWM and PLC to check the connection
P
S A P
 STAR  Status Request  EWM to aks for the current availability of an equipment
S A P
 STAT  Status Message  PLC to indicate that an equipment is temporarily not
P a
available resp. available again
s e
 WT  Warehouse Task  EWM to give an order to the PLC to move a HU
r
U
t
n
 WTCO  Warehouse Task Confirmation  PLC to indicate that a task has been executed
l
e
a
r
 LOCL  Location Left  PLC to indicate that a HU has left a location
n
r
O
e
n
 WTCR  Cancellation Request  EWM to cancel a warehouse task
t
l
n
y
I
 WTCC  Cancellation Response  PLC to respond to a cancellation request from EWM
 SCAN  Scanner Message  PLC to announce a HU at a location
Task Communication
Telegram Types
I
PLC
l y
n
t
O n
e
r
n
r
a
e
l
n
t
U
r
s
a
e
P
S A P
S A P
P a
s e
r
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
Task Communication
Telegram Flow Conveyors
I
EWM PLC
l y
n
t
O n
e
r
Warehouse task
n
r
a
• Scanner (optional)
e
l
n
• WT
t
U
r
• Location left (optional)
s
a
e
P
• WT confirmation
S A P
S A P
Task cancellation
P a
• Cancel request
s e
• Cancel response
r
U
t
n
l
e
Equipment state
a
r
n
• State request (optional)

r
O
e
n
• State
t
l
n
y
I
Task Communication
Telegram Flow Resources
I
EWM PLC
l y
n
t
O n
e
r
Warehouse task
n
r
a
• WT
e
Control of WT Confirmation:
l
n
• Start Confirmation (optional)

t
U
r
• Destination (optional)
s
a
e
P
• WT confirmation
S A P
S A P
Task cancellation
P a
• Cancel request
… same as conveyors
s e
• Cancel response
r
U
t
n
l
e
Equipment state
a
r
n
• State request (optional) … same as conveyors

r
O
e
n
• State
t
l
n
y
I
Task Communication
Bin Address Mapping for Telegram Communication
I
l y
n
t
O n
e
r
Application Data: Map EWM storage bin
n
names to PLC bin names
r
a
e
l
n
t
U
r
s
IMG: Activate Mapping on PLC level
a
e
P
S A P
S A P
P a
s e
r
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
Agenda
Setup Material Flow
I
l y
n
t
O n
e
r
n
r
a
e
1. Warehouse Layout
l
n
t
U
2. Routing
r
s
a
3. Task Creation
e
P
S A P
S A P
P a
s e
r
7. Exceptions
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
PLC Event Processing

Assign MFS Action FMs to Telegram Types
I
l y
n
t
O n
e
r
n
r
a
e
l
n
t
U
r
s
a
e
P
S A P
S A P
CP
P a
s e
r
U
t
Confirm task CP01-CP02
Create new task CP02 – CP11
n
l
e
a
r
n
r
O
e
n
t
l
n
y
WTCO HU 1 from CP01 to CP02 WT HU1 from CP02 to CP11
I
HU 1 arrives at CP02 PLC

Standard MFS Action Function Module
I
l y
n
MFS Action Function Module Mandatory Meaning and Function
t
O n
Fields
e
r
n
r
a
/SCWM/MFSACT_LOC_EMPTY CP, SOURCE HU has left its source location.
e
l
HU
• Retrieves one or all WT(s) starting at this CP and previously sent to the PLC.
n
t
U
• Sets WT subsystem state to “W” (has left source)
r
s
a
• Capacity of the source increases
e
P
• Checks communication point dependencies (trigger subsequent flow)
S A P
S A P
/SCWM/MFSACT_REPLENISH CP, SOURCE Fixed bin is empty.
P a
• If a product is assigned to the bin, replenishment is triggered
s e
r
U
t
/SCWM/MFSACT_SP CP, HU, HU has been scanned at identification point.
n
MFS_ERROR
l
e
• Posts HU to CP
a
r
Precondition: HU logically located at (any) CP or open WT to (any) CP
n
exists. Otherwise Dummy HU is created and sent to clearing

r
O
e
• Cancels any open WT for the HU
n
t
l
• Checks exceptions ( clearing)
n
y
I
• Updates HU: HU type, weight, volume, length, width, height

• Triggers put away strategy ( BAdI needs to be implemented!)
• Creates follow-up task (layout-oriented)

Additional Requirements at ID Point
I
l y
n
Consider material flow restrictions during BAdI „Identification Point Processing“
t
O n
putaway strategy (unavailable equipment /
e
capacity restrictions)
r
n
r
a
e
l
BAdI „Identification Point Processing“
n
Aisle load balancing

t
U
r
s
a
e
P
S A P
S A P
HU errors detected by the PLC (noread, Customize exceptions matching PLC error codes
outline, overweight, HU type)
P a
s e
r
BAdI „Identification Point Processing“
U
Verify HU weight
t
n
l
e
a
r
n
r
O
e
Accept new HU type By default
n
t
l
n
y
I

Standard MFS Action Function Module
I
MFS Action Function Module Mandatory Function
l y
n
Fields
t
O n
e
r
n
r
/SCWM/MFSACT_STATUS Equipment ID Equipment State has changed (CP, segment, segment group,
a
e
(CP, Segment, resource).
l
n
segment group
• Changes state of equipment
t
U
resource),
r
MFS_ERROR • Checks communication point dependencies (triggers subsequent
s
a
material flow)
e
P
S A P
S A P
P a
/SCWM/MFSACT_WT_CONFIRM CP, HU, HU has arrived at CP
s e
MFS_ERROR
• Posts HU to CP resp. storage bin (if not yet there)
r
U
t
• Triggers follow up task (layout oriented)
n
l
e
a
r
n
r
O
/SCWM/MFSACT_WT_CONFIRM_CANC CP, HU, PLC has confirmed or denied to cancel a task
e
n
MFS_ERROR
• Cancels the task (if MFS_ERROR isn‟t set)
t
l
n
y
I
Agenda
Setup Material Flow
I
l y
n
t
O n
e
r
n
r
a
e
1. Warehouse Layout
l
n
t
U
2. Routing
r
s
a
3. Task Creation
e
P
S A P
S A P
P a
s e
r
7. Exceptions
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
Capacity Management
Customize Capacity Restrictions
I
l y
n
t
O n
e
r
n
r
a
e
l
n
t
U
r
s
a
e
P
S A P
S A P
P a
s e
r
U
t
n
l
 Each communication point may have a maximum capacity assigned.
e
a
r
 The capacity is counted in number of HUs (disregarding their size).
n
 If a maximum capacity is entered, a capacity exception has to be assigned.

r
O
 The capacity exception controls the system behavior in case of lack of free capacity.
e
n
t
l
n
 For capacity restriction conveyor segments may be used as well.
y
I
Capacity Management
Exception Settings
I
l y
n
Exception MCAP
t
O n
e
The exception has to be defined for the resp.
r
business context and execution environment:
n
 Business context „Communication Point
r
a
e
 Business context „Segment“
l
n
 Execution environment „Background“

t
U
r
s
a
e
P
S A P
S A P
Internal Process Codes available for Capacity

Restriction:
P a
s e
 STAY – the next warehouse task isn„t created

 NSND – the next warehouse task is created
r
U
t
nevertheless but not sent to the PLC
n
l
e
a
STAY is recommended, if there are alternate
r
n
routes
r
O
NSND is recommended for resources
e
n
t
l
n
y
I
Capacity Management
Discharging Triggers (CP Dependencies)
I
l y
n
CR3
t
CR1
O n
TRR01
e
CR2
r
n
r
a
e
l
n
t
U
r
s
a
e
TCAR
Discharging Table
P
CP02 CP01 CP10

CP03 CP05 CP07
(IP) (IP)
S A P
S A P
CP00 CP04 CP08

CP06
(PP)
CP09
P a
s e
r
U
t
n
l
e
a
r
If there is a HU waiting on CP01 it
n
will be checked, if now a WT can

r
O
e
Discharge Event for CP02 be created and / or be sent to the
n
t
 WT start message with source CP02
l
PLC.
n
y
 WT confirmation message with source CP02
I
 State message „ready“ for CP02

 WT cancellation with destination CP02
Capacity Management
Use Discharge Messages
I
l y
n
CR3
t
CR1
O n
TRR01
Check discharging table for entries for „CP11“
e
CR2
r
n
r
a
WT HU „1“ from „CP11“ to „CP12“ started (state „W“)
e
l
n
t
U
r
s
a
e
TCAR
P
CP02 CP01 CP10

CP03 CP05 CP07
(IP) (IP)
S A P
S A P
CP00 CP04 CP08

CP06
(PP)
CP09
P a
s e
r
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
LOCL CP11 1
I
HU „1“ has left CP „CP11“ PLC
Agenda
Setup Material Flow
I
l y
n
t
O n
e
r
n
r
a
e
1. Warehouse Layout
l
n
t
U
2. Routing
r
s
a
3. Task Creation
e
P
S A P
S A P
P a
s e
r
7. Exceptions
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
Exceptions
Setup Reaction to Equipment Faults
I
l y
n
Two initiators for exceptions: CR3
t
CR1
User and PLC

O n
TRR01
e
CR2
r
n
r
a
e
l
n
t
U
r
s
a
e
For both, exceptions must be allowed in exception customizing TCAR
P
CP02 CP01 CP10

CP03 CP05 CP07
(IP) (IP)
S A P
S A P
CP00 CP04 CP08

CP06
(PP)
CP09
P a
s e
r
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
Exceptions
Allow Supervisor and PLC to Set Equipment Faults
I
l y
n
Supervisor blocks communication point
t
O n
e
r
n
r
a
e
l
n
t
U
r
s
a
Business Context
e
„Communication Point“
P
S A P
S A P
P a
s e
r
Customizing exception MBLK
U
t
n
l
e
a
r
n
r
O
Execution Environment
e
-„A1 Desktop“ (Warehouse Monitor)
n
t
-- A0 Background (PLC)
l
n
y
I
Exceptions
Equipment State Telegram
I
Customizing state telegram types and MFS action function
l y
n
t
O n
e
r
n
r
a
e
l
n
t
U
r
s
a
e
P
S A P
S A P
P a
s e
r
U
t
n
l
e
a
State = <space>, _ or 0 means “OK”
r
n
STAT CP02 01
r
O
e
n
t
l
n
y
CP „CP02“ state „not ready“ PLC
I
Exceptions
Conveyor Segments and Segment Groups
I
l y
n
CR3
t
CR1
O n
TRR01
e
CR2
r
n
r
a
e
l
n
t
U
r
s
a
e
TCAR
P
CP02 CP01 CP10

CP03 CP05 CP07
(IP) (IP)
S A P
S A P
CP00 CP04 CP08

CP06
(PP)
CP09
P a
s e
Set PLC State
r
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
STAT GASSE1 XX
I
Segment group „GASSE1“ state „XX“ PLC
Exceptions
HU Related Exceptions
I
l y
n
CR3
t
CR1
O n
TRR01
e
CR2
r
n
r
a
e
l
n
t
U
r
s
a
e
TCAR
P
CP02 CP01 CP10

CP03 CP05 CP07
(IP) (IP)
S A P
S A P
CP00 CP04 CP08

CP06
(PP)
CP09
P a
s e
r
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
SCAN CP12 HU ? MFS_ERROR 90
I
Noread at scanner „CP12“ PLC
Exceptions
Prepare Transport of Unknown HUs
I
l y
n
CR3
t
CR1
O n
TRR01
e
CR2
r
n
r
a
e
l
n
t
U
r
s
a
e
TCAR
P
CP02 CP01 CP10

CP03 CP05 CP07
(IP) (IP)
S A P
S A P
CP00 CP04 CP08

CP06
(PP)
CP09
P a
s e
r
U
t
Create new HU
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
Noread or unknown HU at scanner „CP12“
Exceptions
Storage Bin Occupied
I
Define an exception code:
l y
n
t
O n
e
r
n
r
a
e
l
n
Assign internal
t
U
r
s
process code
a
e
BINO:
P
S A P
S A P
P a
s e
r
U
Assign an Alert:
t
n
l
e
a
r
n
r
O
e
n
t
Invoke the exception as reaction to the
l
n
y
PLC error code:
I
Exceptions
I
l y
n
t
O n
e
Maintain follow-on action to block the occupied bin:
r
n
r
a
e
l
n
t
U
r
s
a
e
P
S A P
S A P
P a
s e
r
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
Exceptions
I
l y
n
t
O n
e
Implement BAdI to determine a new destination bin:
r
n
r
a
e
l
n
t
U
r
s
a
e
P
S A P
CR3
S A P
CR1
TRR01
CR2
P a
s e
r
... and / or setup default storage bin:
U
t
n
l
e
a
r
TCAR
n
CP01 CP10
CP02 CP03 CP05 CP07
(IP)
r
(IP)
O
e
n
t
CP00 CP04 CP08

CP06
l
(PP)
n
y
CP09
I
Exceptions
Bin Empty
I
Define an exception code and assign internal process code BINE :
l y
n
t
O n
e
MBNE
r
n
r
a
e
l
n
t
U
r
s
a
e
P
S A P
S A P
P a
s e
r
U
t
n
l
e
a
r
n
r
O
e
n
t
Invoke the exception as reaction to the
l
n
y
PLC error code:
I
Exceptions
Bin Empty
I
l y
n
t
O n
e
Maintain follow-on action to block the empty bin:
r
n
r
a
e
l
n
t
U
r
s
a
e
P
S A P
S A P
P a
s e
r
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I

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I n t e r n a l U s e S A P P a r t n e r O n l y

SAP EWM 210_1

SAP EWM Extended Warehouse Management

SAP Service Parts Extended Warehouse Extended Warehouse Additional Features in

Overview Customizing Management

Material Flow System

4. Which kind of equipment may be integrated and which not?

5. How complicated is it to implement it?

7. What should be considered when deciding for MFS?

Business Needs Addressed by MFS

without needing an external material flow

SAP WM SAP EWM

Business Scenario – High Rack Warehouse for

ID Point Put away Removal-HU

Goods Receipt Clearing Goods Issue Empty Pallets

Aisle 1 Aisle 2 Aisle 3

ID Point Put away Removal-HU

conform? Pick Point

Goods Receipt Clearing Goods Issue Empty Pallets

Aisle 1 Aisle 2 Aisle 3

Crane1 Drop point

ID Point Put away Removal-HU

Goods Receipt Clearing Goods Issue Empty Pallets

Requirements – Transfer Car

Aisle 1 Aisle 2 Aisle 3

Task Interleaving. ID Point Put away Removal-HU

available? Pick Point

Goods Receipt Clearing Goods Issue Empty Pallets

Requirements – Capacity Event Triggering

Aisle 1 Aisle 2 Aisle 3

ID Point HU 1 Put away Removal-HU

Goods Receipt Clearing Goods Issue Empty Pallets

• Consider physical capacity of resources (CP,

conveyor segment, transfer car, crane)

• Consider physical / logical state of resources (out

• Real time control of drives

• Keep track of HUs from CP to CP

• Support HU compliance check

EWM Controls Single Transportation Steps

EWM Controls Single Transportation Steps

EWM Controls Single Transportation Steps

EWM Controls Single Transportation Steps

EWM Controls Single Transportation Steps

Documents during HU Transportation

Telegram 4 from PLC (Task Conf.)

Telegram 6 from PLC (Task Conf.)

 Response time around 1 sec*

Two transactions per event

4. Which kind of equipment may be integrated and which not?

5. How complicated is it to implement it?

7. What should be considered when deciding for MFS?

MFS Uses and Extends Existing EWM Objects

MFS Telegrams are Created for

Area Process Type Area

Queue Determination Criteria

Queues are PLC

CONSYS1 CONSYS2 PLC or other sub system

PLC Telegrams Trigger MFS Function Modules

Confirm task CP01-CP02

WT HU1 from CP02 to CP11

HU 1 arrives at CP02 PLC

Alerts & Application Log

Lesson 2 - MFS Integration

 Background warehouse task execution with automated equipment