Manufacturing Execution Steps Overview

<Jürgen Wettengl>

<SAP AG>
 Prerequisites

Required:

 SAP R/3 basic knowledge in Process-Order Processing.

Recommended:

 SAP R/3 knowledge in Process Management

 SAP R/3 knowledge: Production Instruction Sheets

 SAP AG 2006, RKT for <Manufacturing – Execution Steps>, <> 2

 Agenda <Manufacturing – Execution Steps>

Introduction

Solution : Manufacturing – Execution Steps

How to set up and use Execution Steps

Summary

 SAP AG 2006, RKT for <Manufacturing – Execution Steps>, <> 3

 Manufacturing – embedded solution

Measure
Supply Chain Performance Management

Strategize Plan
Supply Chain Collaboration

Supply Chain Collaboration

Supplier
Demand and Customer
Supply Chain Design
Supply Planning

Collaborate
Collaborate

Supply
Supply
Chain Chain
Hub Source Make Deliver Hub
Network Network
Direct Order
Manufacturing
Procurement Fulfillment
Partner Partner

Track
Supply Chain Event Management

 SAP AG 2006, RKT for <Manufacturing – Execution Steps>, <> 4

 Manufacturing - Integral Part of the Supply Network

Service & End Retailer

R&D Services
Maintenance Consumer

1st Tier
2nd Tier 3PL
Supplier
Supplier
Plant Service
Provider

2nd Tier
3PL Warehousing
Supplier
Marketing & Service Service
Sales Services Provider Provider

Manufacturing is the Heart of the Supply Network and is Central to Every

Business Dimension
Materials flow Information flow
 SAP AG 2006, RKT for <Manufacturing – Execution Steps>, <> 5
 Manufacturing Execution - Goals

Flexible and dynamic Execution of the Production Process

 Reduced workload and maintenance effort by providing

reusable methods and parameters (Execution Steps)
 Provide a personalized work environment for fast and
convenient access to different applications and services for
plant personal (e.g. Shift Manager and Process Operator)
 Flexibility and speed through dynamic, event-driven
Production Instruction Sheets (PI-Sheets) with conditional
logic

 SAP AG 2006, RKT for <Manufacturing – Execution Steps>, <> 6

 The Challenge

External System

Master Recipe Process Order

Process Process
Instructions Instructions
Copy
or
Reference

Standard Xstep
Repository

Production Instruction Sheet

 SAP AG 2006, RKT for <Manufacturing – Execution Steps>, <> 7
 Agenda <Manufacturing – Execution Steps>

Introduction

Solution : Manufacturing – Execution Steps

How to set up and use Execution Steps

Summary

 SAP AG 2006, RKT for <Manufacturing – Execution Steps>, <> 8

 Manufacturing – Execution Steps

Execution Steps
 Repository for standardized Execution Steps and Recipe
building blocks
 Can be used by making a reference to them or
copying them
 Flexible change management (versioning, approval
procedures, classical change management)

 Basis for decoupling execution functions from PP-PI

(Master Recipe, Process Order)
 Easy-to-use editor P

 Test and simulation capabilities

 SAP AG 2006, RKT for <Manufacturing – Execution Steps>, <> 9

 The Solution

Execution Step Master Recipe Process Order PI Sheet /

Repository Control Recipe
PI Sheet

SXS XS XS

OPC

Control Recipe

Reactor 1

SXS: Standard XStep

 SAP AG 2006, RKT for <Manufacturing – Execution Steps>, <> 10

 Business Processes Supported

Execution steps can be used in process industries:

 For the creation of the PI sheet from the process instructions

contained within the process order

 To control the creation of confirmations and process

messages in the PI sheet; for example batch data, goods
movements, and quality data

 For the data exchange between the SAP R/3 system and
external control systems based on the industry standard OPC
or the PI-PCS interface

 SAP AG 2006, RKT for <Manufacturing – Execution Steps>, <> 11

 Production Instruction Sheet (PI Sheet) - Example

Soft logon/ Browser based

logoff
PI-Sheet

Adaptable Layout
Generated
Nested Sheets
Material list

Automated processes

Adaptable for specific

industry needs

Confirmations of
Instructions for
Material Digital
Operator
Consumpions Signature
 SAP AG 2006, RKT for <Manufacturing – Execution Steps>, <> 12
 Easy to use X-Step Editor

Simulation Test Prüfung Suche Im/Export Komponenten

Anwendungskontext
XS
Prozeßmeldungen
XS
Prozeßvorgaben
PA Herstellanweisung
PV

MS

I
Signatur

I  Visualisation of Process
Instructions
PV C Externe Systeme
Empfänger
PV
Parameter
XS
Bewertungssymbole
XS
Generierungsumfänge
XS
Standardschritte
XS

 Test and Simulation

Semantic Check: Meldungen .................................... Suchfunktion: Ergebnisliste

Simulation Test Prüfung Suche Im/Export

Capabilities
XS Simulation der Oberfläche mit Default Stylesheet Aktualisieren

XS

PA

PV

MS
 Easy linking to Applications
I

PV C

PV

XS

XS
 Drag & Drop
XS

XS

Semantic Check: Meldungen .................................... Suchfunktion: Ergebnisliste

 SAP AG 2006, RKT for <Manufacturing – Execution Steps>, <> 13

 Execution Steps - Example

Execution Steps for Mixing Tank &1

Check Mixing Tank &1

Fill mixing tank &1 with &2 liter

Heat tank &1 to &3 temperature

Discharge tank &1 automatically

Tank &1 discharge manually

 SAP AG 2006, RKT for <Manufacturing – Execution Steps>, <> 14

 Agenda <Manufacturing – Execution Steps>

Introduction

Solution : Manufacturing – Execution Steps

How to set up and use Execution Steps

Summary

 SAP AG 2006, RKT for <Manufacturing – Execution Steps>, <> 15

 Definitions

 XSteps

 Standard XSteps

 XStep editor

 Standard XStep repository

(SXS repository)

 SAP AG 2006, RKT for <Manufacturing – Execution Steps>, <> 16

 Execution Steps - Process

Repository

Create XStep Tree

XStep XStep
Reference

Carry Out Check

Example
Carry Out Simulation PI Sheet

Can be copied or referenced:

Release Version
- Master Recipe
- Process Order

 SAP AG 2006, RKT for <Manufacturing – Execution Steps>, <> 17

 Creating a Standard XStep for a PI-Sheet

Here is a simple example of a process to create, check, simulate and

release a Standard Xstep. We show here a material list with a safety
instruction. The procedure to create such a Xstep is listed below:

 Create Folder
 Create Standard XStep
 Create XStep
 Assign Destinations
 Define Parameters
 Assign Scope of Generation
 Create Process Instructions
 Check of XStep
 Simulation of XStep
 Release of Version

 SAP AG 2006, RKT for <Manufacturing – Execution Steps>, <> 18

 Procedure – Create Folder

 SAP AG 2006, RKT for <Manufacturing – Execution Steps>, <> 19

 Procedure – Create Standard XStep

 SAP AG 2006, RKT for <Manufacturing – Execution Steps>, <> 20

 Procedure – Create XStep

 SAP AG 2006, RKT for <Manufacturing – Execution Steps>, <> 21

 Procedure – Assign Destinations

 SAP AG 2006, RKT for <Manufacturing – Execution Steps>, <> 22

 Procedure – Define Parameters

 SAP AG 2006, RKT for <Manufacturing – Execution Steps>, <> 23

 Procedure – Assign Scope of Generation

 SAP AG 2006, RKT for <Manufacturing – Execution Steps>, <> 24

 Procedure – Create Process Instruction

 SAP AG 2006, RKT for <Manufacturing – Execution Steps>, <> 25

 Procedure – Create a Long Text

 SAP AG 2006, RKT for <Manufacturing – Execution Steps>, <> 26

 Procedure – Create a Long Text

 SAP AG 2006, RKT for <Manufacturing – Execution Steps>, <> 27

 Procedure – Check

 SAP AG 2006, RKT for <Manufacturing – Execution Steps>, <> 28

 Procedure – Simulate

 SAP AG 2006, RKT for <Manufacturing – Execution Steps>, <> 29

 Procedure – Simulate

 SAP AG 2006, RKT for <Manufacturing – Execution Steps>, <> 30

 Procedure – Release of Version

 SAP AG 2006, RKT for <Manufacturing – Execution Steps>, <> 31

 Prerequisites

Maintenance of XSteps in the Master Recipe :

To ensure that you can maintain XSteps in the master recipe, you
have to create a recipe profile when creating the recipe group.
The new recipe profiles

PI01_XS: Profile for the Process Industry XSteps

PI01XS2: Profile for Process Industry XSteps Optional

are provided as standard for the maintenance of XSteps.

To do this, access Customizing for the Master Recipe and choose

Settings for the Task List Type -> Define Profiles with Default
Values.

 SAP AG 2006, RKT for <Manufacturing – Execution Steps>, <> 32

 Prerequisites

Early Issue of Order Number :

As default, it is only possible to generate an XStep tree in a

process order once the order in question has been saved. You can
also set that an XStep tree is generated, even if it has not yet been
saved.

To do this, access Customizing for process management and

choose Execution Steps (XSteps) -> Set Early Issue of Order
Number.

 SAP AG 2006, RKT for <Manufacturing – Execution Steps>, <> 33

 Example Master Recipe

 SAP AG 2006, RKT for <Manufacturing – Execution Steps>, <> 34

 Example Master Recipe

 SAP AG 2006, RKT for <Manufacturing – Execution Steps>, <> 35

 Example Master Recipe – Simulation PI-Sheet

 SAP AG 2006, RKT for <Manufacturing – Execution Steps>, <> 36

 Example Master Recipe – Simulation PI-Sheet

 SAP AG 2006, RKT for <Manufacturing – Execution Steps>, <> 37

 Example Master Recipe – Simulation PI-Sheet

 SAP AG 2006, RKT for <Manufacturing – Execution Steps>, <> 38

 Agenda <Manufacturing – Execution Steps>

Introduction

Solution : Manufacturing – Execution Steps

How to set up and use Execution Steps

Summary

 SAP AG 2006, RKT for <Manufacturing – Execution Steps>, <> 39

 Features - Summary

Definition:
Execution steps are modules that you use to precisely
describe the execution process.

Usage for :
Creation of PI sheets
Communication between a process order and an external
control system; for example scales or a process control
system
Controlling the creation of confirmations or process
messages in the PI sheet: e.g. batch data, goods
movements, quality data

 SAP AG 2006, RKT for <Manufacturing – Execution Steps>, <> 40

 Business Value

Reduction of time for maintenance of process

instructions

Standard Xsteps can be used as a template or can be

referenced to a standard Xstep

Changes are made centrally in the XStep repository

Flexible Change Management (Versioning, Approval
Procedures, Classical Change Management)
Easy-to-use Editor
Test and Simulation Capabilities
Error reduction

 SAP AG 2006, RKT for <Manufacturing – Execution Steps>, <> 41