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Implementation Scenarios & Architectural

Considerations for SAP MII Implementations


Dipankar Saha, IBM India (SAP Mentor)
3 Key Learning Points
Industry scenarios for SAP MII implementation
Architectural options and best practices for
SAP MII implementation
Implementation approach for global SAP MII
deployment
1. Implementation Scenarios & Use Cases for SAP MII
2. Determining the Right Deployment Scenario
3. Handling Complex Integration & Messaging
4. Managing Plant Data
5. Making the UI That Engages
6. Delivering the Solution For Global Deployment
Agenda
Manual filling and packing line data collection
process to be automated
Integration with multiple SCADA,
Historian, MES for process data collection
User-friendly operator dashboards
Consumer Products
Consumer Products
Chemicals & Petroleum
Chemicals & Petroleum
Integration with MES, LIMS, SCADA for
process monitoring and transaction updates
Relationship of process data points in
Historian Tags with Enterprise assets
Process event management on data point
deviation
Automobiles & Assembly
Automobiles & Assembly
Complex manufacturing process automation
by integrating ERP and MES
Multiple systems for master and transactional
data (BOM, routing) to be integrated with MES
High volume of data transfer from each
system requires guaranteed delivery
Energy & Natural Resources
Energy & Natural Resources
Real-time process & asset visualization
Real-time analytics on process data
Typical Industry Business Requirements for
Manufacturing Systems Integration & Visualization
1. Implementation Scenarios & Use Cases for SAP MII
2. Determining the Right Deployment Scenario
3. Handling Complex Integration & Messaging
4. Managing Plant Data
5. Making the UI That Engages
6. Delivering the Solution For Global Deployment
Agenda
ERP
ERP
MES
MES
Level 0
Level 1
Level 2
Level 3
Level 4
Batch
Control
Business Planning and
Logistics
Plant Production scheduling,
operational Management
1 Sensing the production process,
manipulating the production process
2 Monitoring, supervisory control and automated
control of the production process
3 Work flow / recipe control, stepping the process
through states to produce the desired end products.
Maintaining records and optimizing
the production process
Time Frame
Shifts, hours, minutes, seconds
4 Establishing the basic plant schedule production,
material use, delivery, and shipping. Determining
inventory levels
Time Frame
Months, weeks, days, shifts
Continuous
Control
Discrete
Control
Manufacturing Operations
Management
Dispatching Production, Detailed
Production, Scheduling,
Reliability, Assurance,
SAP MII
SFAC (SCADA / Historian / DCS)*
* SFAC Shop-Floor Automation Control
SCADA - Supervisory Control And Data Acquisition
DCS - Distributed Control System
Positioning of SAP MII in Enterprise Hierarchy
Plant A
Plant A
SAP MII Deployment Architecture
Centralized/Regional Deployment
SAP ERP
Integration
Integration
Production
Planning
Quality
Management
Plant
Maintenance
Materials
Management
Intelligence Dashboards
Human
Resources
SAP MII
MES
Plant B
Plant B
MES
Plant C
Plant C
MES
Plant X
Plant X
MES
Suitable for plants having standard MES packages and/or lesser integration need in individual plants
Suitable for similar ERP-MES integration across multiple plants
Ideal for cross-plant analytics scenarios
E
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P
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SAP MII Deployment Architecture
Decentralized (Multi Plant) Deployment
Plant X
Plant X
Plant C
Plant C
Plant B
Plant B
Plant A
Plant A
SAP ERP
SAP MII
SAP MII
Material
Management
Production
Planning
Quality
Management
Plant
Maintenance
Human
Resources
Intelligence Dashboards
Intelligence Dashboards
E
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P
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SAP MII
SAP MII
Plant
SAP MII
layer
SAP MII
SAP MII
SAP MII
SAP MII
SAP MII
SAP MII
Corporate
SAP MII
(Optional)
SAP PCo
SAP PCo
SAP PCo
SAP PCo
SAP PCo
SAP PCo
SAP PCo
SAP PCo
Suitable for plants having multiple shop-floor systems and large facilities
Easier to cater to the plant-specific integration and analytics requirements
Integration
Integration
1. Implementation Scenarios & Use Cases for SAP MII
2. Determining the Right Deployment Scenario
3. Handling Complex Integration & Messaging
4. Managing Plant Data
5. Making the UI That Engages
6. Delivering the Solution For Global Deployment
Agenda
SAP MII Integration Architecture
How to Handle Complex Integration
MII Portal
SAP ERP
MES
Historian SCADA
Mfg
Orders
Synchronize
Mfg Orders
Process
& Confirm Orders
Analyze Process
Data & Events
Order
Confirmations
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PLM/ECM
S
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M
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BOM/Routing
Mfg Orders Order Conf/GI/GR
Sample Scenario ERP-MES
Manufacturing Order Synchronization &
Plant System Integration
SAP MII Integration Architecture
How to Handle Complex Integration
SAP ERP
MES
Message Services
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P
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PLM/ECM
S
A
P

M
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Scheduled
Job
IDoc/RFC
XML (HTTP)
XML (HTTP)
WebService
M
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s
s
a
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M
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n
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t
o
r
MDO
Mapping BLS
(Async)
Mapping BLS
(Async)
Standard
Custom
Maps SAP Message with
Legacy and vice versa
Persist message header and
message id to correlate messages
Monitor messages with
Business Context
Queries and processes
categorized messages
Process categorized message by scheduler
Persist Message Header and ID in MDO
Correlate stored messages by key fields
Use asynchronous message processing
SAP MII Integration Architecture
Guaranteed Delivery of Outbound Messages
SAP ERP
MES
Message Services
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PLM/ECM
S
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M
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IDoc/RFC
XML (HTTP)
XML (HTTP)
WebService
Standard
Custom
M
a
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p
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B
L
S
MDO
Connection Handler
BLS
Buffer & Forward
WebService
Store outbound messages in MDO
Query and send message to target systems periodically
Message Monitor
SAP MII Integration Architecture
Process Data As Event Notifications
MII Portal
Historian SCADA
Analyze Process
Data & Events
P
l
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SAP PCo
Notification Agent
Event Handler & Processor
Database
Query Agent
S
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P

M
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E
v
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n
t

M
a
n
a
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e
m
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&

A
n
a
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y
s
i
s
Standard
Custom
Generate process events on tag value change in Level 2 systems
Trigger follow-up action on event generation
Store events and analyze with process data
Events
1. Implementation Scenarios & Use Cases for SAP MII
2. Determining the Right Deployment Scenario
3. Handling Complex Integration & Messaging
4. Managing Plant Data
5. Making the UI That Engages
6. Delivering the Solution For Global Deployment
Agenda
Managing Plant Data
Persisting Transactional, Master & Configuration Data
SAP ERP
MES
Mfg
Orders
Message Services
Order
Confirmations
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P
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PLM/EMC
S
A
P

M
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BOM/Routing
MDO
Transactional Data with Header Information,
Master Data
Shared
Memory
Plant specific
configuration data
Standard
Custom
Persist transaction and master data in MDO
from Message Services
Persist configuration data in Shared Memory
Managing Plant Data
Semantic Mapping
Semantic Mapping is used to define relationship
between the tags present in the Historian/SCADA
systems with the corresponding business data entities
typically maintained in SAP ERP, to provide a
business context to the raw process data.
As tag values in Historian are plain time-series data
with no business context attached to it, it is not
possible to analyze them and readily understand the
business impact of the data.
To enable the visibility and deliver intelligence on the
raw process data captured from the machines,
mappings are defined between the tags and business
data objects.
The mapping can be maintained in MDO along with
the hierarchy information in Plant Information Catalog
(PIC), which can be queried at runtime to get the
corresponding tag and subsequently process data
from Historian/SCADA for enterprise data objects e.g.
equipments
16
S
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M
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Enterprise Asset Objects
Asset Tag & Process Data
Mapping UI & logic
K
P
I

&

C
h
a
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t
s

Tag Query
RFC
MDO
SAP ERP
Plant Historian/SCADA
PIC
Standard
Custom
1. Implementation Scenarios & Use Cases for SAP MII
2. Determining the Right Deployment Scenario
3. Handling Complex Integration & Messaging
4. Managing Plant Data
5. Making the UI That Engages
6. Delivering the Solution For Global Deployment
Agenda
Making the UI That Engages
Leveraging Different UI Technologies
Create user interfaces in MII depending on the user role and method of access (minimal user inputs & process intelligence)
Leverage AJAX & XSLT transformation to deliver dynamic user experience
Use SAPUI5 to develop device-independent and engaging UI
Use OData interface in MII with SUP to develop mobile apps
BLS
XSL
HTML UI (AJAX)
HTML
XML
Data
Source
XML
XML
BLS
XacuteQuery
OData
XML
Data
Source
XML
XML
BLS/Illuminator
HTML (UI5)
HTTP
Data
Source
XML
XMLModel
Browser Based UI5
Portal on Mobile
Native Mobile App
Dynamic UI
Based on Data
1. Implementation Scenarios & Use Cases for SAP MII
2. Determining the Right Deployment Scenario
3. Handling Complex Integration & Messaging
4. Managing Plant Data
5. Making the UI That Engages
6. Delivering the Solution For Global Deployment
Agenda
Delivering the Solution For Global Deployment
- IBMs Approach for SAP MII Implementation
Evaluate
Project
Preparation
Blueprint Realize
Final
Preparation
Go-Live &
Support
Review Client
Environment
Prepare
Proposal
Accelerators :
SAP MII Pre-
Implementation
Questionnaire
Collect Detail
Requirement
Define
Implementation
Roadmap
Define
Architecture
Accelerators :
SAP MII Architecture
Decision Document,
SAP MII Solution
Architecture PoV,
SAP MII Effort
Estimation Too
SAP MII Solution Assets
Prepare
Functional
Specification
Prepare
Technical
Specification
Develop
Technical
Object
Perform
Testing
Accelerators :
SAP MII FS & TS
Templates,
SAP MII Development
Guidelines
Setup
Production
Perform Hand-
Over
Prepare for
Go-Live
Accelerators :
SAP MII
Implementation Go-
Live Kit
Go-Live
Monitor
Support
Enhance
Accelerators :
SAP MII
Implementation Go-
Live Kit
Initiate Project
Planning & Kick-
off
Finalize Scope
& SoW
Finalize Quality
Plan
Accelerators :
SAP MII
Implementation WBS
Delivering the Solution For Global Deployment
- Global Multi Plant Deployment
Solution Design
Create a common template solution which can be customized for each plant
For decentralized (plant-specific) deployment create cross-reference project structure in MII
workbench, the top-level project consisting of the core and common functionalities and the child
projects consisting of the plant-specific functionalities
Use different software component for each project in MII workbench so that those can be
deployed/transported individually
Use MII Shared Memory of type map to store system connection information corresponding to
different plants
Change Management & Transport
Use NWDI for content management
Use CTS+ for transport/deploy from DEV->QA->PRD
Use single DEV instance with plant-specific QA and PRD instances for de-centralized installations
Use separate development and correction systems post go-live
Delivering the Solution For Global Deployment
- Accelerating By Solution Assets (REVAMP)
Need monitoring of different events in plants e.g.- Machine breakdown, Valve opening, Process parameter changes etc
Need early warning where it may prevent the loss and can help to take decision much before the actual event occurred
Need actions automatically -without any manual intervention
Event Chain
Consequent Events
(Anticipated)
Parent
Event Actual
Event
Consequent Event
(Executed)
Forced Triggered
Event
Features & Value Proposition
The solution provides a framework to detect
physical events by change in tag values in
SCADA/Historian
SAP MII records the event and provides
dashboards for monitoring and predictive
and process analysis of events
The events are contextually linked with the
enterprise data and process by semantically
mapping the tags with enterprise data
objects
Each event instance can be configured to
trigger chain of events or sequence of
processes in external systems
Event analytics on assets provides
information about assets affected by events
and help in root-cause analysis
IBM Real-World Contextual Event Management Platform
Delivering the Solution For Global Deployment
- Accelerating By Solution Assets (Visual Plant)
Need real-time visibility and awareness of the state of an asset in the plant-floor.
Need a visual representation of asset e.g. how the workcenters are related to each other
Need real-time information of the machine state, order execution, inventory, process parameters, etc
Features & Value Proposition
The solution provides a framework using which the
user can define the asset hierarchy or can import the
same from external systems such as SAP ERP or
third-party MES and persist the same in SAP MII
For each asset (equipment/workcenter/functional
location) the user can define the info-collector
services for both basic and detail view which can be
developed and plugged-in at deployment time or later
The asset hierarchy will be visually displayed to the
user in SAP MII portal
The basic information of individual assets will be
displayed along with the asset hierarchy view with
periodic auto-refresh and detail information on drill-
down in real-time
A visual representation of the asset layout in plant
floor along with real-time information of the machine
state, order execution, inventory, etc can be used as
a monitoring solution and alerting dashboard
IBM Visual Plant & Asset Monitoring Framework
Delivering the Solution For Global Deployment
- Accelerating By Solution Assets (ASMD)
Features & Value Proposition
Using this asset MII administrator can check all
the statuses and system properties along with the
messages and user and BLS/query stats in a
single screen
The solution provides the following monitoring
features:
Displays the status of all the configuration
objects e.g. Scheduler, Data Server, Message
Service, etc.
Displays the BLS/Query stats and user stats
Displays the failed message in the message
service.
Displays the NetWeaver log of the system and
Java System Reports
Provides consolidated system performance
reports
Displays System connection downtime stats and
sends email alerts
Need monitoring of system properties and connections in production support of SAP MII
Need root-cause analysis of system performance issues
Need alerts on connection downtimes
IBM Automated System Monitoring Dashboard
Questions?
Dipankar Saha
IBM India
Email: dipankar.saha@in.ibm.com
Twitter: http://twitter.com/buddydip
LinkedIn : http://in.linkedin.com/in/dipankarsaha
Dipankar Saha
IBM India
Email: dipankar.saha@in.ibm.com
Twitter: http://twitter.com/buddydip
LinkedIn : http://in.linkedin.com/in/dipankarsaha
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