SAP ManufacturingIndustry 4.0 with the SAP software suite

On the road towards INDUSTRY 4.0, the continued improvement and more widespread use of MES functionality – and in all sectors of manufacturing – is of central importance. The familiar MES topics of transparency and traceability – plus efficient personnel management – are now being extended to include system integration and sensor data analysis while also ensuring flexibility and adaptability in production. Open systems, with service-oriented, decentralised architecture and standardised options for interfacing machinery are important preconditions here. Complementing their extensive core functions, MES systems from SAP also have these properties from the outset.

With SAP Manufacturing Execution (SAP ME), SAP has provided a fully-featured and configurable MES system for use in discrete manufacturing.
SAP MII (SAP Manufacturing Integration and Intelligence) is the proven solution for the process industry. Pre-configured solutions from IGZ for bulk production, continuous flow production and filling/packaging build on this by ensuring rapid rollouts and a solid ROI.

Integration with SAP ERP (SAP Enterprise-Resource-Planning) is part of the solution! The MES modules from SAP are the only MES systems on the market that actually offer integration as standard plus a range of other integration scenarios with SAP ERP (SAP Enterprise-Resource-Planning) out-of-the-box. This ensures that ERP integration work will be compatible with later releases.

The IGZ service portfolio not only includes strategic consulting on MES deployment and subsequent SAP implementation as well as direct SAP/system/machinery integration but also covers any and all manual or automated production facilities and shopfloor systems.

IGZ – the SAP Engineers – can look back on a wealth of experience and reference projects both within discrete manufacturing and the process industry.

Our customers' primary objective is a high degree of SAP integration and the increase in efficiency, stability, transparency and quality, as well as reductions in ongoing operating costs.

 

Fields of competences

SAP Manufacturing – machine interfacing

Machine interfacing

With the in SAP Manufacturing Suite integrated component SAP Plant Connectivity (SAP PCO), SAP offers the following options direct machine interfacing, automatic detection of machine conditions and quantities, acquisition and storage of various process data.

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SAP Manufacturing – Effective Plant Data

Effective Plant Data

With SAP ME and SAP MII, all work steps in production can be tracked and monitored on the shop floor without gaps and up-to-date. This means that precise details about the progress and status of production orders are available at all times.

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SAP Manufacturing – OEE

OEE

With SAP OEE, operators of production and manufacturing systems have an instrument available to them that can help to measure and evaluate the availability and performance of technical facilities, as well as the quality rates achieved.

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SAP Manufacturing – Production Control Center

Production Control Center

Graphical planning boards for the detailed scheduling and control of your orders and resources give you quick access to an overview of the status and progress of your current production orders and future scheduling at any time.

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SAP Manufacturing – ERP-Integration

Integration

On the logistics side, SAP provides a platform for production logistics with Extended Warehouse Management (SAP EWM). This close integration between logistics and production can be optimally realised via SAP ME and SAP EWM.

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SAP Modules


SAP ME (SAP Manufacturing Execution)

SAP ME is the MES system from SAP for all your discrete manufacturing needs!
SAP Manufacturing Execution is a high-performance, scalable, enterprise-level manufacturing solution that enables complete, component-level and material-level visibility for both individual and global installations. 

SAP ME supports and enables:  

  • Error-free development and production from day one
  • Detailed modelling of the manufacturing process 
  • Dynamic control and monitoring at WIP level 

In addition, production information is collected and communicated in real time throughout the entire production life cycle. 
The result is an aggregated record of the entire product history. This is stored permanently, thereby fulfilling the statutory documentation requirements and contributing to efficient decision-making.


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SAP MII (SAP Manufacturing Integration and Intelligence)

With SAP MII, SAP provides a web-based, standardised and flexible IT platform for vertical integration in production. This combines the various steps necessary for process-oriented production with SAP ERP. 

As a central information hub, SAP MII extracts and interprets data from various sources (such as shop floor systems), and offers a wide range of monitoring, controlling and control options for process optimisation and increased production efficiency. 

This makes SAP MII the central element of a KPI-driven production process that is characterised by efficiency, availability and quality. SAP MII relies on tight integration with SAP ERP. SAP MII makes it possible to act early, rather than to react, and also to exploit and purposefully control hitherto hidden productivity and quality potential. 

Via our proprietary SAP MII Best Practices, IGZ offers pre-configured solutions for integrated and efficient production processes throughout SAP MII, especially for process industries.


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IGZ Best Practices

Fill + Pack® - Automated filling and packaging lines with SAP MES

For the area of Consumer Products, IGZ provides SAP MII (SAP Manufacturing Integration and Intelligence) Best Practice Fill + Pack, a solution for efficient filling and packaging processes for liquid products or bulk.

Based on SAP MII, IGZ provides modular best practice solutions that enable the creation of transparent processes in automated filling and packaging within the shortest possible time of the plant and company.

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Flow + Pack® – Automated flow lines with SAP MES

With the SAP MII Best Practice FLOW+PACK®, IGZ provides a solution for efficient production and packaging processes in automatic linked production lines.

Based on SAP MII, IGZ provides modular Best Practice solutions that enable the creation of transparent processes in automated production and packaging within the shortest possible time of the plant and company.

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Electronic Work Instruction – Increasing process reliability through online worker guidance

With the Best Practice Electronic Work Instruction, IGZ offers a system-controlled processing of SAP ERP control recipes. The employees are thus guided safely through the manufacturing process of a process order.

The system management is based on the processing of a control recipe by means of process instructions and phases. The control recipe is managed centrally in SAP ERP. Besides the exact guidance of the employee through the control recipe, EWI additionally ensures the manufacturing process by supplying parameters to technical systems via direct connection to SAP MII.

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Extended OEE 4.0 – Effectiveness increase through production key figures

Overall Equipment Effectiveness is a well-known indicator within the TPM (Total Productive Maintenance) concept. It serves as a measure to identify, monitor and optimize availability, performance and quality in relation to the production process.

With the help of measurable KPIs, the SAP ME / MII-based OEE serves to have production services comprehensively in view at all times and to recognize where and why performance losses occur. An order-related profitability calculation can be carried out and goal-oriented countermeasures can be implemented quickly and effectively.

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Order Cockpit 4.0 – Order fine control

Planned production or process orders are made available from SAP ERP (SAP Enterprise-Resource-Planning) (PP) after release in SAP ME/MII (SAP Manufacturing Execution / Manufacturing Integration and Intelligence) for production control.

With the SAP ME/MII-based (SAP Manufacturing Execution / Manufacturing Integration and Intelligence) fine planning (interactive graphic order guidance), current shop floor information, such as the current machine status, can be used to distribute and start the orders on available machines, taking necessary and existing resources into account.

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Energy Optimization – Energy management and optimization

With SAP MII Energy Optimization®, IGZ provides a solution that reduces costs by deriving energy-saving potential. The solution makes it possible to comprehensively visualize energy consumption online and to control it in an energy-optimized manner.

The need for efficient energy use arises with great urgency due to dwindling resources, rising and fluctuating energy costs, temporary supply failures and increasing pressure from the legislature.

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