SAP MES (ME/MII) and Solution Templates

Manufacturing operational excellence means achieving the business goals with minimal resources. In order to survive in today’s competitive global market; organisations need to reduce production cost, cycle time and environmental impact. All while maintaining and improving quality, customer delivery and satisfaction. So, how can you empower personnel with real-time, actionable intelligence to reach operational excellence?

There are multiple options for SAP MES on the shop floor; SAP ME? SAP MII? Both?



Known for being one of the most recognised full spectrum MES applications on the market today, SAP-MES provides the best “end to end”, feature rich MES platform for any business running SAP ERP. Whether your requirements are aligned to SAP ME, SAP MII or both platforms, SAP provides robust and intimate ERP integration capabilities along with full scope MES/MOM functionality needed for companies that are looking for a MES platform that can support them now and into the future.

In business, information is power – but like all power, it needs to be managed appropriately. The answers to the following questions provide valuable insight to the impact MES can have to your operation:

  • How often are you using real-time, actionable business intelligence to make operational decisions?

  • Can you consistently run your plant at the highest level of productivity and maintain quality?

  • How do you track real time operational performance?

  • How can you eliminate the gap and data flow constraints between the shop floor and the top floor?

 

Our consultants have worked with SAP ME and MII extensively. We know how to get the most from your implementation and understand the complexity of managing MES programs long term. Each manufacturing environment has its unique characteristics; the products that are manufactured, the equipment used to manufacture them and the IT systems that need to be integrated as part of the implementation. The result is that more than 90% of all MES implementations will need some form of customization.

 


Our consistent, proven and structured project methodology - from initial discoveries and blueprinting, to go-live and post project support – are key to our 25 year success in delivering game-changing, world-class SAP MES solutions.

SAP MES Templates

The development environment for SAP-MES has been designed to provide certain functionality out of the box. As well as the ability to customize functionality to suit specific needs. With this in mind, RTS has developed various modular (plug & play) re-useable solution templates to quickly meet the requirements of a specific application, as per the below table.

 

These prebuilt templates assist with quicker blueprinting and foster:

  • Project Reduced Risk

  • Quicker Time to Value

  • Scalability

  • Improved ROI

  • Flexibility

Whether you deploy one module at a time or the complete MES suite, the solution empowers the appropriate personnel to gain complete real-time visibility into operational performance, asset utilization, quality, energy management, production dynamics and much more.

RTS Overall Equipment Effectiveness (RTS OEE) on SAP MII

How do you measure and evaluate plant floor productivity? Do you use data or real time actionable intelligence to identify areas of improvement? Can you consistently run your plant at the highest level of productivity and quality? What tools do you use to ensure continuous improvement?

Overall Equipment Effectiveness (OEE) is a way to monitor and improve the efficiency of your manufacturing process. It’s an internationally accepted management tool to measure and evaluate plant floor productivity.

OEE = Availability x Performance x Quality

World Class OEE for discrete manufacturing plants is considered to be 85% or better however, the average OEE score for discrete manufacturing plants is usually 60%.

 

To assist you fulfilling the promise of OEE, RTS Consulting Inc. has developed the RTS Overall Equipment Effectiveness (RTS OEE) solution on the SAP MII platform. This solution, part of an overall manufacturing execution system, empowers manufacturing companies to improve their processes using real time operational information to minimize causes of inefficiency, ensuring quality, consistency, and productivity measured at the bottom line.

The overall goal of the RTS OEE is to help you reduce or eliminate Major Loss Events. This sophisticated solution not only measures the inefficiencies, but groups them into three categories to help you analyze the manufacturing process:

 

1) Downtime Losses are events requiring maintenance

  • Machine Breakdowns
  • Machine Adjustments/Setups

2) Performance Losses are events not requiring maintenance

  • Machine Stops
  • Machine Reduced Speeds

3) Quality Losses are rejects occurring during initial startup & full production runs

  • Machine Startup Bad Parts
  • Machine Production Bad Parts

 

The RTS OEE, seamlessly integrates with the business system and the shop floor infrastructure, providing the following 3 categories of benefits: 

1) Predictive Production Management:

  • Comprehensive visibility to real-time production trending information to address production issues before they occur. 
  • Actionable intelligence to address production anomalies as they happen, driven by immediate e-mail alerts .
  • Ensured order specifications compliance, communicating customized production orders, customers quality information and testing procedures to the shop floor.

2) Fully Integrated Solution:

  • Multi-plant capability: Can be deployed as a standard solution across all plants and sites, regardless of underlying production and IT systems.
  • It allows you to compare plants based on OEE analysis (including cost allocation) to identify “best of breed” manufacturing performers: 
    • Plants / Processes 
    • Production shifts / lines
    • Departments / assets
    • Days / week / weekend 
    • One single system of record for production management, providing robust analytics and consolidating information from all disparate shop floor sources and processes.
    • Increased data transparency & accuracy, automatically recording and delivering to the business system, production information from meters, significant assets, Historians, PLC’s, DCS’s, LIMS.
    • Effective OEE analysis via standard and custom reports.
    • Enhanced user acceptance and learning, through interactive rolebased dashboards.

3) Manufacturing Continuous Improvement:

  • Loss reason code system, captured by the operators during the production process and analyzed later during root cause meetings. 
  • Allowing you to take necessary actions to:
    • Reduce Bottlenecks
    • Implement Machine Operator Training
    • Reduce Machine Setup Time
    • Improve Machine Reliability
    • Maximize Optimal Run Rates and Capacity
    • Eliminate Down Time
    • Optimize/prioritize maintenance tasks
 

Watch this short video clip to learn how the RTS OEE solution on the SAP MII platform, empowers manufacturing companies to improve their processes using real time operational information to minimize causes of inefficiency, ensuring quality, consistency, and productivity measured at the bottom line.

 RTS Overall Equipment Effectiveness (OEE) 

RTS Quality Management Information System (RTS QMIS) on SAP MII

PREVENTING QUALITY ISSUES BEFORE THEY OCCUR

 

How are you ensuring continuous quality improvement across the entire product life cycle?  How fast are you able to respond when a quality issue arises? Does Operations have real-time visibility to quality trends?

 


Quality management is not just about inspection activities and “after the fact” reviews to implement corrective actions. It’s about enabling and optimizing the quality strategy deployment with real-time actionable intelligence to trigger Corrective and Preventative Action (CAPA) from non conformance production.


Capturing data manually, analyzing it once the product has been manufactured, and failing to comply with customer’s “critical to quality” parameters, increases the level of scrap, rework, re-inspection and cost. All of these failures are the difference between “best in class” and “laggards” in quality management systems and manufacturing excellence. 


So often companies have well established inspection procedures, but without a holistic quality solution that integrates data from the shop floor with the comprehensive QM capabilities of SAP ERP and the new SAP Quality Issue Management (QIM) to handle deviations, a closed-loop holistic quality management  system landscape cannot be achieved.

 


So, how can you boost your customer satisfaction, reduce scrap and empower manufacturing personnel with real-time automated information on the shop floor to address quality issues as or even before they occur?


 

The RTS Quality Management Information System (RTS QMIS) on SAP MII


creates a strategic advantage in only 8 - 10 weeks by providing:


 

 

Predictive Quality Management

 

•   Comprehensive visibility to real-time quality trending information to address quality issues before they occur.

 

•   Actionable intelligence to address quality anomalies as they happen, driven by immediate  e-mail alerts  when quality control limits are exceeded.
 
•   Ensured “critical to customer” specifications compliance, communicating customized production  orders, customers  quality information and testing procedures to the shop floor.
 
•   Enhanced decision making for raw material production suitability, by allowing visibility to inspection lot test results and providing instant notifications of “quarantined raw material” to shop-floor personnel.


Global and Integrated Solution


•   One single system of record and analytics for quality management,  consolidating information from different sources (SAP and non-SAP based) and processes.


•   Increased data transparency & accuracy, automatically recording quality & production information from In-Line/Off-Line quality devices, Historians, PLC’s, DCS’s, LIMS & the business system.


•   Effective quality analysis via standard and custom reports, including Statistical Analysis with automatic calculation algorithms for: CPK, Median, Min, Max, Mean, PPM, Standard Deviation, Variance, and much more...


•   Enhanced user acceptance and learning, through interactive role-based dashboards for different staff categories.

 


 


 

Quality Continuous Improvement


•   Continuous Improvement support, analyzing complaints and causes of quality defects in order to take  measures and prevent recurrence.


•   Enhanced quality information through improved visibility of historical and real time quality and manufacturing parameters.


•   Resource use optimization, focusing efforts where changes are most needed to improve quality.


•   Superior customer satisfaction, tying quality “best-in-class” performance to your corporate reputation.


•   Cost savings due to the reduced level of scrap, rework, re-inspection and expenditures. 



Compliance of Batch Manufacturing Quality


   Batch specification compliance and consistency, though the validation of all critical quality processes.


•   Good Documentation Practices (GDP), keeping record of all quality instructions and procedures, allowing you to show that all needed steps were  taken and that the quality was as expected.


•   Batch history and traceability, maintaining the recipe records in a comprehensible and accessible form that permits recalling any batch of product from sale or supply.

 



The RTS QMIS allows transparency to quality and maintenance data in SAP ERP as well as issues and activities in SAP Quality Issue Management (QIM)



80% of all quality issues are repeat issues. Leading edge companies require the ability to capture, continuously improve, and leverage performance

knowledge from lessons learned so that preventive action can be taken.

Manufacturing Execution System with SAP ME and MII

Manufacturing operational excellence means achieving the business goals with minimal resources. In order to survive in today’s competitive global market, organisations need to reduce production cost, cycle time and environmental impact. All while maintaining and improving quality, customer delivery and satisfaction. So, how can you empower personnel with real-time, actionable intelligence to reach operational excellence?


Known for being one of the most recognised full spectrum MES applications on the market today, SAP-MES provides the best “end to end”, feature rich MES platform for any business running SAP ERP. Providing robust and intimate ERP integration capabilities along with full scope MES/MOM functionality needed for companies that are looking for a single platform that can support them now and into the future.


Our consultants have not only implemented SAP-MES for multiple industries, but also helped design the application and have maintained it as a client in real world applications. Our consultants know how to get the most from your implementation and understand the complexity of managing MES programs long term. Each manufacturing environment has its unique characteristics; the products that are manufactured, the equipment used to manufacture them and the IT systems that need to be integrated as part of the implementation. The result is that more than 90% of all MES implementations will need some form of customization. The development environment for SAP-MES has been designed with this in mind along with a modular (plug & play) framework to achieve manufacturing operational excellence.


Whether you deploy one module at a time or the complete MES suite, the solution empowers the appropriate personnel to gain complete real-time visibility into operational performance, asset utilization, quality, energy management, production dynamics and much more; helping you accelerate performance to achieve world-class operational excellence.

 
For more information please see our MES Brochure
 

In business, information is power – but like all power, it needs to be managed appropriately. The answers to the following questions provide valuable insight to the impact MES can have to your operation:

  • How often are you using real-time, actionable business intelligence to make operational decisions?
  • Can you consistently run your plant at the highest level of productivity and maintain quality?
  • How do you track real time operational performance?
  • How can you eliminate the gap and data flow constraints between the shop floor and the top floor?

The MES Suite will help your business address these vital questions. Our consistent, proven and structured project methodology - from initial discoveries and blueprinting, to go-live and post project support – are key to our success in delivering game-changing, world-class SAP MES solutions.

Automotive SAP MES Solution

 

Today, the Automotive Tier 1 business has ever increasing manufacturing performance demands. From product serialisation, detailed individualised product quality data capture, to in-sequence and just in time shipping. Truly an environment where high first pass yields are mandatory and unscheduled downtime is critical to the bottom line. To help clients achieve operational excellence, RTS has developed a SAP Automotive MES solution with the following functionality:

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