Neoris - SAP.com
Transcription
Neoris - SAP.com
Practical Visionaries Neoris – SAP MII Converge, collaborate and increase production in real time! William Noland VP, National Practice Director Sep Confidential 2009 // Neoris 1 Confidential // Do Not Reproduce without prior written permission from Neoris Manufacturing today has some key challenges… • Global Competitiveness is HERE placing tremendous pressure on cost, quality and responsiveness – Manufacturing nodes are being pushed out to distant locations leading to a loss of visibility and control – Asset efficiency ffi i iis a premium, i b effective but ff comparative measures are difficult to achieve – Plants use copies of master data creating compliance and quality issues – Production personnel lack the decision support information to meet their targets – Business and financial impact of production exceptions cannot be monitored or controlled at the enterprise level Confidential // Neoris 2 What companies need to do… Operational Excellence trought multiple plants Confidential // Neoris Real Time response to demand changes and exceptions Consistent meet targets of Cost, Quality and Time 3 What they have today… Integration Challenges Management Challenges “SC Planning (76%), Inbound Materials(67%), Enterprise (56%), ), Factory y Floor PLM ( (70%)” “80 percent of manufacturers want to ensure the same metrics are used the same way across all plants” Aberdeen Group CIO VP LN VP Manufacturing Confidential // Neoris MESA Metrics Execution Challenges Time Lag between event occurring and actionable response is 24 hours to a month” MESA Metrics VP Sales VP Operations 4 Integrating the real-time Plant Floor with the Enterprise poses formidable challenges… – Disparate Plant System Landscape – A Typical yp manufacturing g p plant will have between 10 and 50 shop p floor automation systems (SFA) – A multi-site manufacturer will have between 40 and 700 SFA systems across its enterprise “Less Less than 1% of respondents indicated that manufacturing data is automatically integrated with ERP with no manual intervention” Managing Automation and AMR Research September 2005, Customer Survey Confidential // Neoris 5 Manufacturing and Enterprise business processes need to be synchronized … ? ERP How are we hitting our targets? Total Cost of Production and Variance Labor and Resource Productivity Order Fill Rates and Cycle Times Fixed and Variable Asset Utilization DISCONNECT DISCONNECT ? MES SFAC* ? What’s happening during every shift? Material availability and consumption Capacity availability and utilization Schedule changes Product Genealogy tracking and QM What’s happening at each line? Cycle Times / Operating Efficiencies Machine Breakdowns / Unplanned Downtime Quality Index Predictive Maintenance requirements SFAC - Shop Floor Automation and Control Systems MES – Manufacturing Execution Systems DCS – Distributed Control Systems Confidential // Neoris 6 The Gap Factory Confidential // Neoris Enterprise 7 The Gap Impact Enterprise SAP ERP (4.6 +) DCS to SAP QM IDI PI-PCS P There is not a single way to See EAI tools Measure Integrate Manufacturing Operations MES to SAP Custom to SAP LIMS to SAP Factory Confidential // Neoris 8 The solution–Manufacturing Operations Management with SAP MII Adaptive Manufacturing Manufacturing Operations SAP Manufacturing (mySAP ERP) across the Enterprise Manufacturing Integration Confidential // Neoris SAP P MII Manufacturing Manufacturing by SAP MII enables adaptive manufacturing Excellencewith the Synchronization synchronizing manufacturing operations A Single Version Reliablyof produce enterprise “A to deliver “a a single version the truth truth” and of the manufacturing Truth” to target with drive excellence. year-to-year process and cost improvement Manufacturing Intelligence 9 MII Capabilities and Components “SAP MII is the only enterprise class manufacturing intelligence solution on the market today.” Alison J. J Smith AMR Research Shopfloor and other systems Confidential // Neoris 10 MII Data Sources Databases Files Spreadsheets BW Confidential // Neoris 11 MII Unification of Manufacturing Analytics Predefined Manufacturing Analytics Manufacturing Dashboards in ERP MII Decision Support Applications MII and VC Custom Analytics Confidential // Neoris MII UI Simplification MII Six Sigma and Quality Analytics MII Dashboard Components 12 SAP MII and its Impact on Shareholder Value Business Goal Increase Revenues Increase Profits – Reduce Operating Costs Increase Shareholder V l Value = Reduce Working Capital Reduce Costs + Reduce Fixed Capital Confidential // Neoris Perfect Plant Levers Financial Strategies Meet Time and Volume Targets: IImproved d order d fill rated t d & on-time ti shipments hi t Faster response to changed demand Higher volumes/yields with shorter lead times Increased throughput Minimize Operating Costs: Reduce overtime & exception resolution costs Less waste, less WIP, and finished goods inventory Elimination of redundant manual data entry costs Reduced cash cash-to-cash to cash cycles Meet Quality and Regulatory Compliance: Lower quality/EH&S compliance-related penalties Minimize reject, j , rework,, and warranty y costs Higher value per product through better quality Optimize Return on Assets: Increased overall asset utilization (OEE) Reduce physical asset base 13 Dashboard of KPI’s Monitoring Confidential // Neoris 14 Dashboard of Equipment’s Monitoring Confidential // Neoris 15 Dashboard of Production Control Confidential // Neoris 16 PDA Application Confidential // Neoris 17 Emails with Alerts and Graphics Confidential // Neoris 18 Dashboard for Safety Monitoring Confidential // Neoris 19 On line process monitoring Confidential // Neoris 20 OEE (Overall Equipment Effectiveness) Confidential // Neoris 21 SAP MII ‐ Selected Client List Confidential // Neoris 22 SAP MII ‐ Print Screens Confidential // Neoris 23 SAP MII ‐ Print Screens (Cont.) Confidential // Neoris 24 Innovation – Videowall Confidential // Neoris 25 Innovation – Videowall War Room Video Remote PC WWW LAN PCs Controller iPhone ERP Confidential // Neoris BI CRM … 26 Innovation – Videowall (Cont.) Agribusiness / Ethanol Utilities Confidential // Neoris Oil & Gas CPG 27 Innovation – Videowall (Cont.) Confidential // Neoris 28 Innovation – iPhone / Videowall http://www.youtube.com/watch?v=j3dwOTsR2cs Confidential // Neoris 29 About Neoris Confidential // Neoris 30 Who we are Neoris is a global business and IT consulting firm. We establish long-term relationships with our clients, helping them improve performance throughout the different stages of their business. Our unique global delivery model, combined with cutting-edge IT services, allows us to innovate, build, deploy and operate business solutions that are both practical and visionary. Employees: Founded: Offices: Fast Facts Confidential // Neoris Headquarters: Presence: Over 3,000 2000 18 Miami, Florida USA U.S., Latin America, Europe, Middle East, Africa 31 Global Coverage SAP SAP Centers Centers Software Software Development Centers Development Centers Global Global Presence Presence Monterrey.Mexico Buenos Aires.Argentina Bogota.Colombia Sao Paulo.Brazil Budapest.Hungary Madrid Spain Madrid.Spain Monterrey.Mexico Culiacan.Mexico Buenos Aires.Argentina Rosario.Argentina Budapest.Hungary Madrid Spain Madrid.Spain Argentina (*) Brazil (*) Colombia (*) Chile (*) Peru Venezuela Mexico (*) Trinidad & Tobago Guatemala El Salvador USA (*) Canada Spain (*)) Spain ( Portugal Hungary (*) Poland France United Kingdom Netherlands Germany United Arab Emirates (*) Morocco Oman Turkey Qatar Australia (*) Office locations Confidential // Neoris 32 SAP MII - Leadership and Experience Watch Portal Comp. App. OEE and Production Notification Comp. App. SAP MII Excellence Center (Brazil) First MII project i LATAM in SAP MII Award (Petrobras) 20 MII Certified Resources 2006 SAP MII Award (Fosfertil) 2007 Konitech acquisition in Brazil 70 MII Certified Resources 2008 2009 SAP MII Award (CINTAC) SAP MII Award (PEMEX) 1st MII 12.0 implementation in LATAM SAP Preferred Partner for LME Video Wall Comp. App. 40 MII Certified Resources Confidential // Neoris 33 Awards SAP Awards Strategic Reference Award ASUG Impact Award I Innovative i SAP Project P j Implementation I l i New Solution Introduction Number of certified consultants in Latin America Strategic Implementation - SAP MII SAP Award of Excellence IDC Latin America Semi-annual IT Services Tracker 2nd Largest IT Consulting firm in Latin America 2nd Largest Systems Integration firm in Latin America 1st IT Consulting firm in Mexico 1st Systems Integration firm in Mexico 1st Custom Application Development firm in Argentina Global Services 100 Leader – South of the Border Top 10 Best Performing Infrastructure Providers Brown-Wilson Black Book of Outsourcing h O t i ti A i B Bestt N Nearshore Outsourcing company ffrom L Latin America “50 Best Managed Global Outsourcing Vendor” The IAOP Global Outsourcing 100 Top p 10 companies p by y Industry y Focus: Oil & Gas Companies with most employees in Latin America Confidential // Neoris 34 “Looking to use SAP MII? Consider work by Neoris to make SAP MII a reality. reality With a history of improving SAP implementations in South American operations, we’re impressed with the company’s ability to make SAP MII vision a reality. reality.” AMR Research Cool Technologies for Improving Consumer Products Value Networks Jul, 2009 Confidential // Neoris 35 Q&A Practical Visionaries Confidential // Neoris Appendix Case Studies Confidential // Neoris 37 Whirlpool www.whrilpool.com Whirlpool Corporation (Whirlpool) is a global manufacturer and marketer of home appliances. It manufactures and markets a line of appliances and related products, primarily for home use. use The Company Company’s s principal products are laundry appliances, appliances refrigerators and freezers, cooking appliances, dishwashers, air conditioner equipment, mixers and other small household appliances. Whirlpool also produces hermetic compressors for refrigeration systems. It manufactures in 12 countries under 14 brand names and markets products to distributors and retailers around th ld the world. Confidential // Neoris 38 Whirlpool Project Overview In order to better align several of its departments and areas – such as Inventory, Raw Materials, Production and Management – and provide them with better visibility over its internal processes, Whirlpool decided to integrate its shop-floor systems with the ERP. The solution chosen by the company was SAP MII. By creating Composite Applications – developed in a web environment – all production and business teams began to have personalized access to tools that improved the visibility and monitoring of the production process. The implementation of SAP MII took place gradually, without the need to stop production. Today, all intermediate phases of production are integrated and accounted for in real-time by scales that use radio-frequency and bar codes. The project enhanced the shop-floor lay-out and the utilization of raw materials, consequently, improving the efficiency of the production process as a whole. Project Results • Better visibility and real-time control of the process variation (plastic injection). • More accurate purchases of raw materials, which improved planning and inventory control. • Production optimization, by avoiding constant pauses in the process to evaluate inventory, which also reduced the amount of overtime. • Better control of recycled materials • Better control and definition of responsibilities among the departments involved Confidential // Neoris 39 Whirpool Confidential // Neoris 40 Klabin www.klabin.com Klabin S.A. is a Brazilian company engaged in the integrated production of market pulp, paper and paper products. The Company owns 17 mills in Brazil, spread in eight different states, states and one mill in Argentina. Argentina Klabin operates in a variety of market segments related to forest products, market pulp, paper and paper products. Its line of products comprises papers, folding boxboards for packaging, corrugated cardboard boxes, industrial bags and logs. In addition to supplying the raw material, wood, to the pulp and paper mills, Klabin's Forestry Unit is the major Brazilian supplier of logs for timber and lumber. The Forestry Unit supplies the Company's mills with approximately six million tons of wood per year. Confidential // Neoris 41 Klabin Project Overview To maximize quality and cost effectiveness in its plants and enable growth, Klabin determined to replace much of its analytics software with a single, strong manufacturing monitoring and the SAP Manufacturing Integration and Intelligence (SAP MII) application. SAP MII was best at satisfying the firm’s criteria, especially tight integration with core SAP software and the manufacturing execution systems layer. The result was a complete OEE and root cause analysis system for manufacturing improvement. Klabin began with the most complex of its plants, Telemaco Borba in the state of Paraná. Systematically a team from Klabin and its partner Neoris integrated SAP MII with the manufacturing controllers in the plant and rewrote existing processes. The team finished in five months, on schedule and within budget, before moving on to other Klabin plants. Altogether Al h Klabin’s Kl bi ’ savings i reach h into i the h millions illi off dollars d ll annually ll at just j the h first fi plant, l with i h much h more to come. Because of its success, the Telemaco Borba plant was honored with a distinction in 2008 – the Total Productive Maintenance (TPM) Award from the Japan Institute of Plant Maintenance. Klabin is the first Brazilian pulp and paper company to win the first degree of this award, which recognizes ongoing improvements and standards of industrial excellence. Project Results • Saved millions of dollars annually • Reduced scrap by 700 tons, worth US$500,000, per year (1st plant only) • Maximized asset utilization • Implemented an advanced static process control application fed with accurate, online information • Improved p and streamlined connectivity y with 1 application pp to integrate g many y data sources Confidential // Neoris 42 Klabin Confidential // Neoris 43 Thank you Confidential // Neoris 44 4444