Suman Mukherjee - SAP MII: Functional and Technical Concepts in Manufacturing Industries
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SAP MII: Functional and Technical Concepts in Manufacturing Industries: summary, description and annotation
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Leverage the flexibility and power of SAP MII to integrate your business operations with your manufacturing processes. Youll explore important new features of the product and see how to apply best practices to connect all the stakeholders in your business.
This book starts with an overview of SAPs manufacturing integration and intelligence application and explains why it is so important. Youll then see how it is applied in various manufacturing sectors.
The biggest challenge in manufacturing industries is to reduce the manual work and human intervention so that the process becomes automatic. SAP MII explains how to bridge the gap between management and production and bring sound vital information to the shop floor in real time.
With this book youll see how to ensure existing manufacturing and information systems share a common interface for all users in your enterprise.
What Youll Learn
All levels of SAP manufacturing professionals.
This book starts with an overview of SAPs manufacturing integration and intelligence application and explains why it is so important. Youll then see how it is applied in various manufacturing sectors.
The biggest challenge in manufacturing industries is to reduce the manual work and human intervention so that the process becomes automatic. SAP MII explains how to bridge the gap between management and production and bring sound vital information to the shop floor in real time.
With this book youll see how to ensure existing manufacturing and information systems share a common interface for all users in your enterprise.
What Youll Learn
- Understand the functional aspects of SAP MII
- Implement SAP MII in different Manufacturing sectors
- Explore new technical features of SAP MII 12.x
- Integrate scenarios with SAP MII
- Discover practice guidelines
All levels of SAP manufacturing professionals.
Suman Mukherjee: author's other books
Who wrote SAP MII: Functional and Technical Concepts in Manufacturing Industries? Find out the surname, the name of the author of the book and a list of all author's works by series.
Jessica Shaw
Ravendra Singh
Ganesan P.
Gary P. Pisano
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Suman Mukherjee and Saptaparna Mukherjee (Das) 2017
Suman Mukherjee and Saptaparna Mukherjee (Das) SAP MII1. SAP MII Overview
Suman Mukherjee 1 and Saptaparna Mukherjee (Das) 1
(1)
Kolkata, West Bengal, India
This chapter explains the manufacturing industry. It also discusses SAP MII and how it fills the gap of information flow between management and production. Along with that, it explains the history and features of SAP MII introduced in the manufacturing sector and how to work with it.
Concept of Manufacturing
Manufacturing basically involves the steps that convert the different raw materials into a finished product. It starts by collecting the material or creating the semi-finished material. It also involves designing the final product. These materials are modified and processed further to get the desired result. In industrial production, raw materials are converted into finished goods. Such finished goods are produced on a very large scale and can be further sold to other manufacturers depending on demand and needs. These finished goods may also be sold to wholesale buyers who in turn prefer to sell them to retailers, who then sell them to end users or customers. Thus, this selling and buying is a long chain, where different buyers and sellers are involved and use the manufactured product.
Revolution in Manufacturing
In earlier days, manufacturing was limited to a few experts and was carried out on a very small scale. After the industrial revolution, this changed and manufacturing became large scale but the processes were still completely or partially manual and very time consuming.
Later, with the modernization of manufacturing, the processes became very complex and multiple sub-components were added to the process. Shopfloor machines were connected to PLCs and sensors and the sensor data was stored in DCS, LIMS, SCADA, and Historian devices. Along with that, enterprise modules like production planning, master data governance, and others, came into the picture so that management could also get an understanding of production and its related business statistics. This created a pyramidal structure of layers in the industry where at the ground level are the shopfloor machines and the highest level includes ERP (Enterprise Resource Planning).
There was a gap between the production shopfloor and the enterprise module, as there was no scope to connect them. Higher management never received real-time or near real-time information from their production plants. Other challenges, such as getting wrong information from the production plants, was also observed as data collection and production information gathering were manual processes (and therefore included human error).
Manufacturing Processes
The manufacturing industry follows certain process steps to complete production. This process is different for each type of industry domain. There can be some set of processes for automobile industries, but they will not be the same for the pharmaceutical industry. In the upcoming chapters of this book, we explain the domains and their expected processes, including explaining where SAP MII is best fitted and where the capability of SAP MII can be fully utilized.
Types of Manufacturing
In the manufacturing industry, there are multiple types of manufacturing depending on industry standards, region, and even continent. Although the processes and sub-processes are different for each domain, at a very broader level, there are two types of manufacturing:
- Discrete manufacturing
- Process manufacturing or batch manufacturing
Discrete Manufacturing
Discrete manufacturing is the production of distinct items where part of the final production can be further manufactured separately and can be used as input to the next manufacturing module in the whole process. In short, discrete manufacturing consists of all the produced components that are easily identifiable and can be de-assembled to get the main input component at which the process started.
The processes involved in discrete manufacturing are not continuous in nature. Sometimes, each process can be individually started or stopped and can run with different production rates. The final product can be produced with single or multiple raw or semi-finished inputs.
Discrete manufacturing runs with two conceptsone is low volume and high complexity and another is high volume and low complexity. Low volume with high complexity can change as market need changes, and high volume with low complexity needs a very good inventory capacity and proper control over the inventory. Controlled, high quality inventory stock reduces production cost as well as waste.
Good examples of discrete industries are automobile, electronics, aviation, etc., where the main concept is to assemble multiple raw or semi-finished products and create a new finished material which might not be the same as the base material.
Process Manufacturing
Process manufacturing, commonly known as continuous manufacturing , refers to the production of any finished material, which is the same base component ingredient but in a different form. In process manufacturing, products can be manufactured in lots or batches. Bulk production is possible in this case. The raw material consists of several ingredients that were mixed, churned, transformed, and converted to manufacture the final end product. This means the end product of process manufacturing cannot be de-assembled back to the raw materials.
In process manufacturing, processes are continuous in nature. Final products are manufactured only after a good market survey and a good understanding of the customer demand.
Quality control is a major factor during process manufacturing. A strong and very good quality control process involves quality inspection to pass any batch or lot. A batch can be recalled for retesting and verification at a later stage for quality reasons. Due to the huge scale of produced components, the quality check always happens in batches, which provides for more efficiency and speed. When any issue is found in the quality samples of any batch, the complete batch may be scrapped. In-process quality control is also possible. Based on a quality report, the raw material ratio can be changed to make the final product better.
Process manufacturing requires a good warehouse management to store stock, and this might require backup warehouses sometimes. Process manufacturing also monitors the product expiry date and distributes product across the market as per the requirement.
Good examples of process industries are chocolate, food, oil, natural gas, lens, medicines, etc.
Filling the Gap in Manufacturing
The biggest challenge in the manufacturing industry is to reduce the manual work and the human intervention during work so that the processes can be automatic. Another challenge is to fill the gap between management and the shopfloor, which closes the gap between business and production. Manufacturing industries have been looking for a solution that can provide real-time integration so that management can get real-time visibility of production happenings. This allows management to plan production accordingly.
There were a few local solutions available in the market to fix this gap, but these homegrown solutions were only fit for certain manufacturing environments. It was a revolution in the manufacturing industry, when in 2005, SAP AG launched the product SAP xMII. It was not only capable of providing near real-time integration, but could also provide a rich visualization to the user interface solution. This allowed management as well as the shopfloor to use reports to make key decisions. SAP xMII got an overwhelming acceptance in the manufacturing industry and so is SAP MII currently.
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