SAP智慧智能工厂规划建设解决方案

SAPPerfectPlant完美工厂制造解决方案SAP为制造业提供一站式解决方案企业营运层企业营运层制造执行管理制造执行管理制造集成与智能工厂管理层设备自动化及控制◎2011SAP中国.版权所有.第2页SAP全新的制造系统架构：The“PerfectPlant”全球化的运筹力跨系统的整合力跨系统的整合力orders,materials,assets,labor,excessivework-in-processbuildup跨厂区KPI仪表板CostCostVariance%-2006Q1CostVariance%2006Q130FTTABE"PABTNE8AdaptabilityAdaptabilityWorldwide-Variancefrom2006Q12006Q1ParityBenchmarkOverheadVarianceVarianceOverheadCostCopvright2007BusinesObjecsSA.AIRightsReserved.crystalxcelsius·收货(批次)EQ\*jc3\*hps75\o\al(\s\up14(·工单管理),存连接与看)◎2011SAP中国.版权所有.制造执行在制品(批次/单件)追踪与记录第5页供货商化联机测试仪器系统测试仪器系统生产排产与生产计划的协调公司总部周/天调整各地工厂小时调整◎2011SAP中国.版权所有.生产计划(含时序第7页生产流程(Routing)建立■在制品状况物料状况投入产出■在制品状况物料状况投入产出生产效率分析品质报告设备效率分析设备效率分析物料良率分析■人员效率分析■订单完成状况■物料上料确认■物料上料确认物料短缺看板物料追溯■机台状况及属性管理■工具使用状况及预防性维护■机台状况及属性管理■工具使用状况及预防性维护■质量检测和测试数据采集■员工培训认证监控■上岗工时审计与成本生产过程管理文件偏辑查者操作酵助主要圃任何次序组圆同步组ASSEMBLE并行工序粗加工精加工1精加工2*版本：条件路径ASSEMBLEPROGRAMTEST包装完工组装电机测试包装完工顺序操作自动操作嵌套工艺路线自动操作嵌套工艺路线返回(初始)路线逻辑◎2011SAP中国.版权所有.第9页序列化追踪序列化追踪物料消耗物料消耗数据收集要装的组件要装的组件KenA图形化指示1111GPS-SIGNALGPSsihaDCGROUPPARAMETERVOLTAGEVOLTAGE-INDOPERATIONELECTRICALRESOURCEDEFAULTASSEMBLE数据收ISFC:30001406,数据收集组：GPSSignalStrengthSpeakerVolumeFrom:tracy.wiese@Sent:Fri2/9/20073:32PMTo:TracyWieseSubject:SPCViolation生产不稳定，xxx出现问题LCL:LSL:LCL:LSL:Feb9,200715:31:43Localintranet◎2011SAP中国.版权所有.第11页◎2011SAP中国.版权所有.第12页信息透通的供应链管理-产品生产履历e工单或批号基本信(人)作业员SFC:6064-003ShopOrder:FMC-100OrderType:ProductionProcessLot:WorkCenter:e(地)工作站Dashboard-WindowsIr(地)生产机台□口区URES,ASSY-TVE-GRAPHIC,3-DDRAWING,TEST-PROCEDURES,ASSY-T(时)时间6064/ANOTEescription:Startescription:StartActivityDate/Time:Nov19,20081J1:09PMRouter/Rev:6064/AStepID:010StepID:010User:DEMOActualComponent:P1000006442Rev:AQtyAssembled:1Date/Time:Nov19,200810:03:11PMCustomerOrder:Customer:Item/Rev:P1000006064/ADeBOM/Rev:P100006064/-Router/Rev:6064/A-10KSIPRESSURETEST:299LimitValues:Min:300PSITEST:29LimitValues:Min:27Max:3归DCGroup:GAS-TESTDescription:GASTEST110KSIPRESSURETEST:300LimitValues:Min:300PSITEST:30LimitValues:Min:27Max:310KSIPRESSURETEST-15MIN:292LimitValue10KSIPRESSURETEST-3MIN:59LimitYalues:115KSIPRESSURETEST-15MIN:448LimitValue15KSIPRESSURETEST-3MIN:88LimitYalues:LABEL-CHECK:OKTEMP:204.649925231934LimitValues:Min:200搜集之工程数据参数INYENTORY_ID_SFC:6442-0003ActivityCode:COMPLETEDescription:CompleteActivityDate/Time:Nov19,200810:03:29PMRouter/Rev:6064/AEQ\*jc3\*hps60\o\al(\s\up6(Activ),EMO)StepID:020User:DEMOINYENTORY_ID_SFC:211363-03StepID:020User:DEMOInventoryID:214922-03INYENTORY_ID_SFC:214922-03□□ActivityCode:ASSYPTDescription:AssemblyPointActivityDate/Time:Nov19,200810:09:14PMRouter/Rev:6064/AStepID:020User:D口BOMComponent:P153124Rev:ADescription:PADSTUDW/NUTInventoryID:153124-01Done工单完工报工与ERP无缝集成成本核算工人绩效考核成本核算工人绩效考核客户满意度其他精益管理SAPERP&SCM业务数据订单完工订单报废消耗废料解锁电子指导书工程变更管理返修原材料返修预报警成本核算-SAPERP訂單1000025F002訂單類型PPO1標準生産訂單工廠1000最佳實務工廠台灣物料F002成品二計劃敷量119.047KGkg實際敷量119.047KGkg成本要素成本要素《内文〉來源幣别B總計劃成本z總實際成本95000002折舊費用PL1004/AVT295000005其他製造費用PL1004/AVT50其他製造費用095000001直接人工PL1004/AVT1直接人工■158601000生産投入1000/H00158601000生産投入1000/R011058601000生産投入1000/R0015,81258601000生産投入61,68361,683-58601000生産投入25,645原料95000003動力費用PL1004/AVT32,000動力費用■11,90595000004維修費用PL1004/AVT4雄修費用■11,905OVR◎2011SAP中国.版权所有.第14页eeSAPxApp-MicrosoftInternetExplorerprovidedbyAT&TWorldNetServiceFileEditViewFavoritesToolsHelpBack→×Search案FavoritesMedia因32)E-mailsApplicationSharingISendInstantMessaceIStartChat|馨MyPortalContactsISearch□MyQualityMyProductionInitiativesAlertsProductDataThroughputTime|ManufacturingMyQualityMyProductionInitiativesAlertsAnalysisAnalysisStatusCostingTransactionsDowntimeByFrequencyL10EE(80.06)DowntimeByFrequencyL10EE(80.06)■LINE1:FILLERA:CAPJAM〔3〕■LINE1:FILLERA:MOTORTRIP(1)■LINE1:FILLERA:NOPRODUCT(1)LINE1:FILLERA:OPERSTOP(1)#ofOccurrences■LINE1:FILLERA:INFEEDJAM(638)■LINE1:FILLERA:CAPJAM(221)LINE1:FILLERA:NOPRODUCT(71)LostProductiveLostProductiveTimeL3SpeedL4Speed□区EquipmentStatusStartedLineMachineReasonEndedLostTimebeenrescheduledforApril14thQualitySpecialOpsispleasedtowelcomethefollowingnewteammembers:AnnaKournikova,HeidiKlum,andBridgetFondaFILLERAFILLERBMIXER1MIXER2MIXER3OFFLINEMAINTDIRTY○LINE1FILLERALINE1FILLERALINE1FILLERALINE1FILLERA◎2011SAP中国.版权所有.第15页设备/工具状况监控2122232425262721222324252627X-RayX-RayStopAnahypsAlertTypeUSERLCERTJOL2010-03-02T09:07:31ResourceUser1DDescnpbonSITE_AOMINAssinedusercertifcaticnooholdXRAY0002010-04-23T06:31:24PIOPLACSTTE_aOMINASSEMBLY_sTOP◆8002010-05-07T06:59:06DEFAJLTAssemblyhasstoppedduetounplanneds职BFEAKDOWN8002010-05-10T20:55:00wELORIG1SITE_ADMINPLantBredoan+Severity800AlertTypeSeverityDateTimeResourceusertDDescniptonUSER_CERT_HOLr5002010-03-02T09:07:33INSPECTIONSITE_ADMINAssignedusorcertificationonholdXRAY8002010-04-23T06:31:24PICKPLACESITE_ADMINALERT-XRayContaminationDetectedA5SEMEY_STOP8002010-05-07T06:59:06DEFALLTSITE_ADMINAssemblyhasstoppedduetoanunplannedissueBREAKDOWN8002010-06-10T20:55:00WELDRIG1STTE_ADMINPlantBreakdown·Sevenity800ActiveEActiveEActvtLocatiorDesnotionATimeBTimeActualDeta%AchìIAIAAnayssDYo01TESTw502位depp50.936.77-71L1DY002TESTetdeshaoecer30.634.3121.356.0Y905TESTchkAMsevoperd42.747.82224117.1OY006TETBSScaleNap3nti6.06.74118.1oY008TESTalsssystem55.462.1156.722.84157.4DY009TESTcalteraLmingCul4145.80Y010TESTws02tdepexp65.373239954366.?or011TESTstapepefte73.582.3375.24586.2oY012TESTStapesdnpef30.734.44671.80r013TEST2aespeftetATP0.90.94670,7or014TESTchkZCAPmeassvse47653.3169.071.64738.90Y017TESTApneumabcloop52.158.444.1●33.78.64772.5or018TESTCMMFrange96.0100.4×L.003TESToheckhseStabu88.89.5×L005TESTOheckBeamSize55.4×DisturbanceNotifictions-StatusMonitorDNTypeSeverityStatusUser1DDesorptionNC400Open203PetNion-ConformunceonmeadTool400ClotedPoetToolmusingShortage600OpenPietPat402.243.344notavalable机台状态图-设备经理ViewHomeO区SAP-Lehmann,RalfAdministratorMyMII0010DataServices0020Visualization0030Dashboarding0040Analytics0050ERPIntegration0070SCMIntegration0080SDN□0090BusinessObjectsDashboardXcelsiusGridGaugesPolishedMultipleDashboardDashboardRefineryPlantFloorStatusMachineStatus③2009SAPACHEMA2009 Pump0385,7Pump0185,5IPressure0192,51Pump0290,4IPressure0287,6◎2011SAP中国.版权所有.第17页设备整体效率(OEE)报告-设备经理ViewPOperationsOper.ExcellenceInventoryPOperationsOper.ExcellenceInventoryLevelOEEOOOOOOO◎2011SAP中国.版权所有.第18页SAPEnterprisePortal6.0-MicrosoftInternetExplorer可于ERP及MES中查询同一笔工单完成进度并显示在同一个页面中ITelOWelcomeuservcCollaborationlSearchAdvancedSeWorkInProcessManufacturingOrders(SAP)ManufacturingOrderOrderQuantity2.300,00PCEQ\*jc3\*hps33\o\al(\s\up23(8),1)0EQ\*jc3\*hps33\o\al(\s\up23(0),0)SAPCompletionStatusOrderWorkcenterCompletion(%)Estimcompletion2005-04-21T17:08:16YaterialInflowNetThroughput可以透过MII函数汇整来自不同系统的参数，计算出新的KPI呈现SCADA/HMIServices◎2011SAP中国.版权所有.SystemsSystemsSPC/SQCSystemsSystemsSystems第19页第19页XMIIXMIIFor:ProductFamily-2For:ProductFamily-2ASSY(99.53)ASSY(99.53)TEST(99.51)PACK(99.46)SHIP(99.52)▲2409.50For:ProductFamily-2厂别、线别…等)进行良率分析与监控厂别、线别…等)进行良率分析与监控SamsungEU◎2011SAP中国.版权所有.第20页Anytime,Anywhere,AnyDevice结合MII&BO可达到随处可取实时整合的绩效营运信息，迅速订定有质量决策◎2011SAP中国.版权所有.第21页ITTRaytheonAEROSPACETEXTRON◎2011SAP中国.版权所有.JABIL