SAP MII Project Overview
SAPPHIRE
May 17, 2011
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Jay Monahan Dell - SAP Perfect Plant Lead
Description: Over 15 years systems design experience across multiple ERP package platforms (SAP &
Custom), with experience in multiple industries including Automotive, Metals, Chemicals, Food, Internet
Applications & Logistics Services. As SAP Perfect Plant Lead, responsible for planning, designing,
managing & executing shop floor projects leveraging SAP MII.
Phone: 412.606.8001
E-mail: [email protected]
Bill Edmonds B&G President and CEO
Description: Employed at B&G Manufacturing Company since 1976 in various capacities. Participated in
the first MRP implementation at the company (MAI Basic 4) in 1988. Involved with ERP System selection
and implementation of SAP (R/3-3.1h) in 1998 as well as upgrade to ECC 6.0 in 2008.
Phone: 215.996.3331
E-mail: [email protected]
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Headquarters - Hatfield, PA
130,000 sq. ft. facility
162 employees
Distribution Center Houston, TX
40,000 sq. ft. facility
8 employees
Business Activities:
Fastener Manufacturing & Distribution
Catalog Products
Engineered Products
Medical Device Manufacturing
Machine Tool Manufacturing
Privately held business since 1946
Third generation of family ownership
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Serving a wide variety of Industries Worldwide
Two Product Distribution Channels
Independent Fastener Distributors (Indirect)
OEM Manufacturing Companies and End Users (Direct)
Two Sales Channels
Call Center Hatfield, PA
Internet Sales
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1997 ERP Selection Process
1998 Go Live SAP R/3 Version 3.1h - Initial Implementation:
Accounting (FI/CO)
Sales & Distribution (SD)
Material Management (MM)
Production (PP)
Quality Management (QM)
2008 Upgrade to SAP ECC 6.0:
Document Management
Production Scheduling
Tooling & Gages (PRT)
2009 Purchased SAP MII to address the following topics on the
Employee Portal:
Labor Confirmations in Real Time
Schedule Visibility
Operator Performance Feedback
Kitting Tooling & Gages
Paperless Factory Floor
CNC Program Downloading
Inspection Results Recording
Real-time Machine Monitoring
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Selection of Development/ Implementation Partner:
Initial choice resulted in failure lost 1 year
Evaluated three candidates Selected DELL Services
Strategy and Diagnostic Session (4-6 weeks):
Developed vision for multi-phase project
Approved Scope for Phase I & Deployment Strategy September 2010
Operator Dashboard
Production Activity (Labor & Quantity Confirmations)
Schedule Visibility (Work Sequencing)
Production Order & Document Visibility
Productivity & Quality Feedback
Supervisor Dashboard
Production Employee Overview with Drill-down to detailed
activity
Maintenance Functions
HR Module
Maintenance Functions
Note: Items moved to Phase 2
Time and Attendance Payroll Interface
Work Center Capacity Overview
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Deployment Strategy:
Initial - Medical Manufacturing (20% of plant activity)
Timeframe:
Phase 1 started in October 2010 - go-live in January 2011
Resources:
Dell 2-3 staff
B&G 1 full-time and 3 partial
Phase 1 Scope:
MII Software Upgrade to latest version
Hardware & Network Evaluation (servers and wireless network)
Write Detailed Functional/Technical Specifications ( 200+ pages)
Coding
Testing
Training
Weekly Status Update Meetings DELL Sharepoint
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Assemble Team
Establish schedule
Review Business
Objectives
Review Current
Business Processes
Project Prep
Management Review
Conduct Workshops
Review Plant
Operations
Summarize Workshop
Results
Create
SAP MII Roadmap
Update
Project
Charter
Project Phases
Staffing Requirements,
Timeline & Cost Estimates.
Example Operator Dashboard
Highlight Project Benefits
Workshop
Preparation
2 Day Session
6 to 8 participants from Norwich
SAP MII Requirements Planning
SAP CO Review
Define /Prioritize Requirements
Identify Phases, Staffing
Requirements & Timeline
Timeline (July 2010 to August 2010)
Requirements Matrix
Assumptions
Review findings with Norwich
Management for Project Approval
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SAP ECC 6.0
SAP MII
Key: = Phase 2 = Phase 1
(1) Quantity & Labor
Confirmations
Production
Work Center Grouping #1
Medical Device Area
ADP
Quality
(18) Administration
Bar Code
Software
= Out of Scope
Work Center Grouping #2
Work Center Grouping #3
Work Center Grouping #4
Work Center Grouping #5
Work Center Grouping #6
Work Center Grouping #7
Work Center Grouping #8
(2) W/C Dispatch List
(3) Production Overview
Detail
(4) Production Overview
Detail
(5) Document View
(Drawings, Procedures etc.)
= Phase 3 = Phase 4 = Phase 5 = Phase 6 = Phase 7
(6) Time & Attendance
Machine Data
(11) Machine Setup
(12) Tooling Data
(8) Inspection Results
Reference
(10) Document View
(Drawings, Procedures, etc.)
(7) Production & Quality
Feedback
Machine
Control
(9) Usage Decisions
(15) CNC Programs
with Comments
(16) Machine Alarms
(17) Inspection Results
(14) Cycle Time
(13) Cycle Count
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MII Supervisor Portal
Real time status of production employees
Active Operations
Productivity Metric
Quality Metric
MII Operator Portal
Active Operations
Dispatch List
Operation Details
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Select
Employee to
view Operator
Portal
MII Operator Portal
Gateway to the Paperless
Factory
MII Production Order View
BOM (Material Level)
Production Operations
BOM (Production Step Level)
Operation Text
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Select to
view
Production
Order Details
Select Active
Operation to
Stop
Select from
Dispatch List to
Start an
Operation
MII Operator Portal
Forced Confirmations
Assures accuracy of
Operator Data Input
MII Conformations
(Rules Based)
Quantity Good & Scrap
SAP Reasons for Scrap
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MII Production Order
View
Connection to SAP
Document Management
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MII Reporting
Work Center Capacity Planning
Custom Grouping and Alerts
Work Center Loading Analysis
Active Operations
Work Center Dispatch List
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Real-Time Shop
Floor Visibility in
the Palm of Your
Hands!
Employee
Group
Performance
Metrics
Individual
Employee
Performance
Metrics
Line
Grouping
Performance
Metrics
Individual
Line
Performance
Metrics
Employee View
Work Center View
Dell Streak 7
Or Other JQuery
compatible Devices
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Machine
Monitoring
Inspection Results
Recording
Tool presets
Inspection
Gages
Tooling
Kitting
CNC Programs
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Go-Live Issues (From the week of January 31
st
)
The most common complaint is not in the application, but the discipline on the plant floor.
Internet Explorer Browser Issues (aka Blocked Pop-ups and Java issues).
Feedback from the Shop Floor: (February 2, 2011)
Simple user interface.
Easy access to Production Scheduling and Detail information.
Document Management Positive feedback from operators, positions B&G for paperless shop
floor.
Interesting Fact: How do you know if a go-live is going well?
- Only 1 SAP MII coding issue was found in the first 6 hours of go-live and you feel comfortable
enough to let your Dell SAP MII Technical Architect leave the plant.
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Reasons For Success:
On the Day of Go-Live:
Dispatch system performance (from 30-90 seconds to 2-3 seconds)
B&G modeled SAP MII after Shoptrac transactions
Training: Early and often (2-3 weeks prior to go-live)
Project Resources:
Experienced resources from both B&G and Dell were dedicated to the success of this
project.
Dell Project approach (Example Detailed Functional Design)
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Bill Edmonds - B&G President and CEO
Phone: (215) 996-3331
E-mail: [email protected]
Jay Monahan Dell Director/SAP Perfect Plant Lead
Phone: 412.606.8001
E-mail: [email protected]
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