Solutions for Model AG (Weinfelden, Switzerland), Model Group (Opava, Czech Republic) and Aarepapier (Niedergösgen, Switzerland)
Optimising existing production KPI reporting
As a first step, we took SAP MII as our basis to analyse the existing KPI reporting tool of a market companion and then raised the potential to optimise performance and visualisation. Using these results, we then optimised the desktop display resolution for 13 reports. The bar graphs and 2-D visualisation of process values were improved in five reports which led to an increase in user acceptance accordingly.
Determining production output based on waste statistics
- Production output, among many other things, is measured by the amount of waste generated at Model AG. In the past, cardboard waste and scraps arising from production were manually read and registered in accordance with the number of cardboard bales produced by the BOA cardboard compactor. Today, the meter reading is transferred in real time from the Siemens cardboard compactor controller to the SAP MII and displayed online in graphs/tables (including the history). This KPI is also displayed in production on multiple large production monitors scattered around.
Consolidation and upgrading to the latest SAP MII release
- In 2015, several older SAP MII systems (Release 12.2) were consolidated into one system and then migrated to the latest SAP MII Release 15. Internally developed production projects were also migrated to Autexis IT AG’s latest MES release at the same time. The HTML5-based interface greatly appreciated by users is an important innovation as the
new production KPI dashboard enables proactive production Management.
- The expansion into a global production cockpit is being developed on a modular basis in SAP MII so that more plants, divisions and production machines can be integrated in a subsequent phase. Another goal is to develop the production cockpit in a modular and configurable fashion so that the Model IT employees can expand it on their own using the required expertise. The KPIs (e.g. net productivity, total productivity, capacity utilisation, etc.) are calculated based on imported production data (e.g. sheets produced, configurations per order, downtimes, uptimes, max. capacity, etc.). Production data and KPIs are displayed in line diagrams and column diagrams and can be compared, even across different machines. KPIs are also visualised on large production Monitors.
Model Group, Opava (Czech Republic)
Creating a detailed concept for introducing MES to the Opava plant (Czech Republic)
- In 2014, the Model Group decided to implement an SAP ME system at the Opava plant in the Czech Republic – one of the largest European production plants – for economic and strategic reasons. A detailed concept (Business Blue Print) was drawn up in an initial phase, defining how to connect the production machines using the existing machine connectors and how to develop and implement 15 production reports based on the detailed requirements document provided by Model.
- We connected 17 production machines to the new MES via SAP PCo and Kepware OPC in the follow-up project (implementation phase). Existing WAGO controllers were re-engineered so that further machines can easily be connected by Model employees in the future. Based on the detailed concept, 15 KPI charts, i.e. downtimes, MTBF charts (meantime between failures), MTTR charts (meantime to repair), OEE charts (overall equipment effectiveness) and defect charts, were developed and implemented. During implementation, Model Opava's IT staff in Villmergen were trained on how to develop reports so that Model can develop more reports itself. More reports in the Czech Republic, Slovakia and Germany are in roll-out planning.
Process integration in the paper mill simplifies paper scheduling
- Vertical integration with the data hub (based on SAP MII) optimises processes between production and planning between SAP ERP and the GSE scheduling system in the paper mill. Purchase orders for raw materials (waste paper) are also simplified and automated. Incoming goods are recorded in the scheduling system when raw materials are delivered to the paper mill and then automatically posted to the SAP ERP system’s materials management system in order to reduce administrative work, avoid incorrect input, eliminate supplier overdelivery and always keep the inventory recorded in the SAP ERP system up-to-date.
New KPI reporting provides Aarepapier with an overview of production
- Paper production today lacks transparency and there are no possibilities to draw comparisons between paper mills. The new KPI reporting (PDF form) gives management an optimal tool to compare and measure the two production plants (benchmark). The source data for KPI visualisation is taken from three operational databases, consolidated and calculated according to standardised models. For each paper mill, the daily report visualises the net production output (linear chart), the loss factor (triangle chart showing availability, quality and performance) and the performance losses in a clear and simple form. Net production and OEE (bar chart), among other things, are impressively laid out in the monthly Report.