Electronic Work Instruction – Increasing process reliability through online worker guidance

Secured online guidance through the manufacturing process

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

The system guidance 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. In addition to the precise guidance of the employee through the control recipe, EWI additionally secures the manufacturing process through the parameter supply of technical systems by means of a direct connection to SAP MES.

EWI records the performed process steps by confirmations from the employee or by reading out process parameters from the technical systems. The manufacturing process is fully documented via feedback to SAP ERP.

Functional overview

  • ERP integration
    Vertical integration of the process order by means of control recipe and process messages via uniform PI-PCS interface.
  • Process data transfer
    Direct transfer of phase-dependent preset values such as times, temperatures, plant settings, etc. to the respective production plants.
  • Online worker guidance
    System-supported guidance of the worker through the individual phases of a process order for a reliable production process and reduced processing times.
  • Paperless production
    Digital display and integration of current production-related documents and media such as process and work instructions. Reduction of paper and manual handwriting during the manufacturing process.
  • Integrated QM processing
    Early detection of qualitative deviations by recording inspection characteristics during production. This enables rapid decentralized corrective action to reduce losses.
  • Integrated performance data acquisition
    Fully automatic recording and feedback of order-related machine and personnel performance data to determine key figures.
  • Process control
    Logical linking of relationships enables optimal process control with automatic override of optional phases during individual operations.
  • Notes & specifications
    Display of hazardous material and handling instructions dynamically from EH&S.

Benefit

  • Error prevention by means of active guidance through the manufacturing process
  • Online documentation for traceability, audits, etc.
  • Continuous batch tracing
  • Direct connection of technical components for simple manufacturing processes
  • Uniform feedback and documentation structure when connecting process control systems
  • Integrated QM processing for early error detection and avoidance of qualitative deviations
  • Digital signature via RFID

Key Facts

  • Safe guidance of the employee through the production steps PP-PI
  • Control of production equipment and specification of process parameters
  • 100 % traceabillity through automated process data acquisition and evaluation
  • Provision of up-to-date production-related documents and safety instructions
  • Integrated QM processing
  • Highest process reliability even with complex, dynamic recipes

Efficiency & reliability

  • Central recipe management in SAP ERP
  • Decentralized processing of the recipe in EWI
  • Direct connection of the technical systems of a production
  • System control for over 50 default types of a control recipe
  • Easy expandability to additional default types
  • Digital display of hazardous substance information
  • Ergonomic dialogue management of the employees
  • Completely paperless processing and documentation

SAP MII references