Níall Ó Cinnéide17th October 2018

Connecting Top Floor to Shop Floor Preparing for the Factory of the Future at SKG

Connecting Top Floor to Shop FloorInspirational Quote Adjusted Slightly:

‘”Technology is nothing. What’s important is that you have faith in people, that they’re basically good and smart, and if you give them tools, they’ll do wonderful things with them.” - Steve Jobs -

What’s also important is that you have faith in people (and align a lot)‘”Technology is nothing quite important.

(and creative problem solvers)

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• SKG at a Glance• SAP Solution Landscape• Choice of SAP MII • Solution Architecture• Achievements & Benefits • Lessons & Recommendations • The Future

SKG At a glance

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EUROPE AMERICAS

EUROPE TURNOVER

N O . 1

8.6

ONLY

N O . 1 €

in corrugated boxes & kraftliner container board

Pan-American producer of containerboard & corrugated

billion in revenue in 2017in Bag-in-BoxTM

Geographic reach

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EMPLOYEES CONTINENTS COUNTRIES FACILITIES CUSTOMERS

346,000 35 64,000370

Our breadth of operations…This Presentation’s Focus is on PaperWho we are

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FORESTRY

103,000hectares forest

plantation

RECYCLING

6.2 Milliontonnes per annum recovered paper

PAPER

7.0 Million tonnes per annum

PACKAGING

10.8 Billion m2 per year

SAP SCM for Supply Chain. SAP ECC for FI, CO, MM, PM,

WM, PP, SD, VC. SAP BW/BI for reporting.

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Scope: Solution Landscape for Mills

ECCERP Central Component

BIBusiness

Intelligence

SCMSupply Chain Management

GreyconX-trim

MIIManufacturing Integration & Intelligence

PCoPlant Connectivity

HistoriansE.g. OSISoft

Other Shop floor E.g. QM SQL DBs

SAP MII for Production Execution & Quality Management.

SAP PCo for alerts and data acquisition.

POProcess Orchestration

Legacies

Other Non-SAP

SAP PO for integration with legacy info systems.

It’s an SAP product. Flexible tool set for building

composite applications on common foundation.

Flexible architecture (centralised and/or at the sites).

Connect once, reuse many times e.g. historian is used for multiple composite applications.

Templates by SAP & 3rd parties e.g. batch manufacturing, CBM.

Matches our internal competencies.

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Why SAP MII? Drivers & Decision – Robust, Flexible, Efficient, Supported

Integration with other SAP Products

MII

E.g. Historians, PLCs

MII Front-End MII Data Store (SQL)MII Business LogicComposite Application A: Production Execution

Composite Application B: Quality management

Composite Application C: Condition Based Maintenance

PCo

E.g. Vibration Monitor E.g. QM, SQL DBs

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Solution Architecture: Understanding & Bridging the Layers

Establishing the principles:• Understand the nature of the

data/how it is organised.• Understand the audience and

use of the data.• Agree what goes where.

DCS Distributed Control System

Display, Set and Exchange Data

Historians Data Store & DisplayTime Series/Persistent

MII Data StoreRelational/Dynamic

OPC Server Data Exchange

PCo Data Exchange

OPC = Open Platform Communications

There are exceptions:e.g. A layer is sometimes skipped.e.g. Data sent from MII to Historian.

PLC Programmable Logic Controller

Monitors & Controls Things

MII

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Achievements: Scope of Main Functionality Implemented…More in the Pipeline

ECC

Shift book

Notifications

Messages/Instructions

Time Loss

Checklists

Ad-hoc Data Acquisition

Shift Calendars

BIReporting

Dash-boarding

Quality Management

Quality Targets

Laboratory Input

Paper Profile

Status Management

Worklists

Inheritance

Production Execution

Blocks/Cut Plans

Recipes

Live Costing

Machine Settings

Production Registration

Winder Queue

Shop Floor/Other

Historians/PLCs

Autoline/Paperlab

Weigh Scales

Winder/Core Cutter

Conveying

Other

SKG common MES with automated data acquisition (background). Deep integration with SAP ECC e.g. BOMs, Routings, Functional Locations…

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Achievements: …Immediate and Easy to Use

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DEEP & NEAR REAL-TIME INTEGRATION OF

SYSTEMS

BEST CONCEPTS AVAILABLE IN ONE SOLUTION FOR ALL

AUTOMATED DATA COLLECTION

ONE SOURCE OF TRUTH & VISIBILITY

PROCESS HARMONISATION &

GOVERNANCE

Business Benefits - Standardised and Harmonised Platform with Bench Marking in a Paperless Environment

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SKILL SET REQUIRED IS EXTENSIVE E.G. MII,

ECC, OPC, SQL, HTML, PLCS, PROCESS

CONTROL, ETC…

NEED TO MANAGE CHANGES

THROUGHOUT MULTIPLE SYSTEM

LANDSCAPES

TESTING CAN BE ‘EXCITING’ AS OFTEN

WITH ‘REAL/LIVE’ DEVICES...

CHALLENGING TO ENSURE TEST

SCENARIOS COVER ALL POSSIBLE CONDITIONS

END USER TRAINING IS QUICK AS SOLUTIONS

ARE INTUITIVE

Lessons Learned: Implementing SAP MII is Different…

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NEED TO HAVE COMMON LANGUAGE, UNDERSTANDING AND

STRATEGY

DATA IN THE SHOP FLOOR IS OFTEN

IMPLEMENTED USER CENTRIC & NOT

ENTERPRISE CENTRIC

EACH SHOP FLOOR DEVICE CAN BE

DIFFERENT - EVEN WHEN THEY LOOK THE

SAME MAKE

RELIABILITY OF SENSORS…NEED TO BE

ABLE TO ADD CORRECTIONS

DON’T TAKE ANYTHING FOR GRANTED

E.G. TIME STAMPS & TIME CHANGES

Lessons Learned: Getting Enterprise Suitable Data from Shop Floor Systems.

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Align

Understanding:Scope, roadmap,what goes where,who does what.

Involve

Stakeholders from all strata: lines of

management, SAP experts, local IT, process control.

Explore

Quickly kick over the rocks: connect to the shop floor, make sense of the

data and monitor it.

Iterate

Iterative not waterfall…multiple

development cycles, frequent testing and

feedback.

Contingency

That what is automated, should

also be possible manually.

Recommendations: People, Exploration, Iterate and Backup

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Insights

More data, more visualisation,

more insights.

Integration

Further integration of information

system processes.

Optimise

Semi/automatic optimisations within

governed parameters.

Predictive

Continue evolve from real-time and condition based - to

predictive.

Cloud/Edge

Cloud services to generate further

insights and deliver value through Edge

processing.

What comes next?

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Thank You for Listening to Our Journey So Far…Any Questions?

Questions?