Digital Manufacturing @ Deloitte

Manufacturing execution systems (MES) make production systems smoother and more traceable, especially in cases where the manufacturing is done on a global scale, supported by complex supply chain networks. In these scenarios, companies need to focus on their core competency, i.e., their product and its manufacturing, as well as learn, maintain, and grow their IT infrastructure as they digitize processes.

The new cloud-based MES system (SAP DM) eliminates IT infrastructure maintenance and simplifies scaling. Not only is DM highly scalable due to its inherent cloud-based technology, but it also provides near real-time transparency on a global scale, enabling the development of custom dashboards with either a global or a granular single plant focus. SAP DM takes these capabilities one step further by introducing transparency and real-time integration from all layers of the system.

DM enables the manufacturing industry to innovate with the agile, efficient, and sustainable capabilities of cloud. This system supports features both in execution of production tasks (through DMe) as well as analysis for deep insights gained through seamless integration between the top floor business systems like ERP with the shop floor production equipment in real-time.

Smart factory for discrete and process manufacturing industries

Production systems can be categorized in two ways: discrete manufacturing and process manufacturing. Each is used to produce a specific type of workpiece or product. The Smart Factory team has already built a reputation as leaders in discrete manufacturing by demonstrating the latest technology and delivering projects for global automotive manufacturers. In Düsseldorf (Germany), the Smart Factory  will showcase a state-of-the-art discrete manufacturing line that manages to demonstrate, in a small footprint, the various technologies implementing robotics, 3D printing as well as a MES system for complete control and traceability of the production of a Lego toy digger.

To implement a fully functional DM system and to develop and demonstrate the various functionalities, the Smart Factory team chose process manufacturing as a use case. 

Deep dive – smart chemical production and recipe management

It is not enough to have a new cloud-based manufacturing execution system to orchestrate the process manufacturing use case at the Smart Factory in Düsseldorf. The team went one step further to implement several innovations within the DM system. 

During the development of the use case, it became clear that DM offers more extensibility options than its predecessor SAP MES. The custom plugin and custom UIs allow the use of customized logic to trigger an action or perform a specific activity that can be linked to a management rule immediately after a specific event occurs in production. POD extensions enable the flexibility to visualize the UI that best fits the process and makes it intuitive for the operators. Standard plugins are already available in the POD designer for quick setup.

The process manufacturing line uses four stations:

• Filtering station
•  Reactor station
• Mixing station
• Filling/ packaging station

In short, the line demonstrates the automated process starting from the filtering of the raw material to the packaging of bottles with the final product. Setting up the master data in DM was quick and easy thanks to the simple User Interface (UI). Each station in the FESTO line is set up independently and the whole system is integrated into the ERP system S4 HANA to receive orders. The execution of this production line can be done through DM and the KPIs are visible via the custom designed dashboards.

In the upcoming versions, the global insights and other features will be brought to the embedded SAC. 

This system will be open for interested professionals to see at our Smart Factory in Düsseldorf.

For further questions, please contact us.