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Maximizing SAP in Mining and
Metals Operations
Stephan Kotze SAP Mining and Metals Forum
Mannheim – Germany
September 2012
Copyright © 2011 – 2012 Accenture All rights reserved.
Accenture literally ‘wrote the book(s)’ on Lean Six Sigma, MES and is a thought leader in Operations Excellence
Lean Six
Sigma for
Service – Best
Sellier
Conquering
Complexity – Best
Seller
Lean Six
Sigma – Best
Seller
Innovation in
Manufacturing
Fast Innovation – Best Seller
Smart Growth:
Innovating to
Achieve High
Performance
MES Guide for
Executives
A Guide to applying
S95
Driving Global MOM
transformation
programs
What is Lean Six
Sigma – Best
Seller
Doing More with
Less – New Book
Business Process Oriented
Implementation of Standard
Software
High Performance through
Process Excellence
Industrial Process
Optimization
Performance
Assessment of
Control Loops
Operational Excellence Operations
Management &
Automation
Business Process
Lifecycle Management
Quality
2
Copyright © 2011 – 2012 Accenture All rights reserved.
• SAP for core operations
considered low functional fit.
• “Start with the basics”.
• More often than not = back
office capabilities.
• Extend as you mature.
Mining & Metals companies have significant opportunity to aggressively drive additional value from Operations.
Traditionally SAP clients often stayed clear of using SAP in core operations.
Market focus
& positioning
Distinctive
capabilities
Performance
Anatomy
• Demand for increased levels of agility drives requirement for
tighter integration of Operations with Business management.
• Increased modernization and simplification of application
landscape:
SAP Industry solutions
Increased application of Advanced Control and MOM* solutions
• Partner solutions: Mature accelerators and partner building
blocks further extent SAP into core operations.
* MOM = Mining/Metals Operations Management 3
Copyright © 2011 – 2012 Accenture All rights reserved.
Mining/Metals companies are unlikely to become High Performers ….
…… if they cannot become High Performers in Operations Management!
Ensure predictable availability of production facilities
Ensure production process stability
Optimize end-to-end value chain
Optimization
Opportunity
Immediate
Opportunity
(Variability Reduction)
Current Plant Status Good Practices Potential
4
Copyright © 2011 – 2012 Accenture All rights reserved.
Business Capabilities naturally extend across solution boundaries in Operations Management
… and all domains need to operate in synchronisation to achieve High Performance
5
Plan & Schedule
Execute
Collect Data
Monitor
Performance
Analyze
Performance
Improve
Field Devices
Plant Control
MOM*
ERP
BI
* MOM = Mining/Metals Operations Management
Copyright © 2011 – 2012 Accenture All rights reserved.
In Operations, value is enabled by Mining/Metals Operations Management capabilities
….. and monitored/tracked/reported by ERP.
Process
Variable
StdDev = 0.342%
StdDev = 2.43%
StdDev = 0.043%
StdDev = 0.495%
After Before
Reducing process variability..
. . . drives a cost reduction and
productivity increase
And creates a new baseline for
further improvement
Previous Process
Variability
Improved
process
New operating point
established
Sample Client Experience
A large mining company needed to
increase throughput and generate a roadmap for continuous
improvement. Together we:
• Assessed value for various
customer-related elements including variability control and
throughput increase
• Developed an implementation
roadmap including project prioritization, champions,
sponsors, timelines, and value
capture profile
• Developed follow-up processes for tracking progress and
generating new ideas for the
pipeline
• Implemented Quick Hits of up to 40% reduction in variability, 4%
increase in productivity, and 7%
reduction in energy consumption
Production
increase
Cost
Reduction
6
Copyright © 2011 – 2012 Accenture All rights reserved.
Opportunity presents itself in the end-to-end integration of Operations Management Processes
… both vertically as well as horizontally.
Quality Management Request & Response
(Product Releasing, Product Certification)
QOM
Transactional Data Repository
Master Data
Management
Master Data Repository
Quality
Specifications
Dimensional
Specifications
Material
Definitions
Production
Orders
Internal
Quality Specification
Order Confirmation
Material
Lots
Quality
Results
Product
Evaluation
Results
Quality
Yield
Results
Material
Movement
Results
Internal Quality
Specifications
Product
Classification
Results
QOM
Internal Request
Management
Quality Specification
Releasing
In Process Waiver
Approval
Product Classification
Product Evaluation
Non LIMS
Quality Results
Data Collection
Samples Taken
Data Collection
Quality Analysis
In Process
Waived
Orders
Test Scheduling Samples
Taken
Results
Requested
Sales
Orders
Customer
Requirement
Customer
Waived
Orders
SAP SD
SAP QM
SAP PP
Sales Order
Processing
QM Order Confirmation
Customer Waiver
Approval
Master Data Repository
Quality
Specifications
Dimensional
Specifications
Material
Definitions
Master Data
Management
Transactional Data Repository
Requested
Sales
Orders
Quality Specification
Order Confirmation
Customer
Requirement
Order Confirmation
Dimensional
Specification
Confirmation
Product
Certification
Quality Specification
Releasing
Customer
Requirement
Releasing
Dimensional
Specification
Releasing
QM Product Releasing
Production Order
Processing
Transactional Data Repository
Confirmed
Sales
Orders
Production
Orders
Confirmed
Sales
Orders
Transactional Data Repository
Confirmed
Sales
Orders
Customer
Requirement
Customer
Waived
Orders
Customer
Waived
Orders
MES Production Order Management
Transactional Data Repository
Production
Orders
Material
Lots
Product
Classification
Results
MES
Work Order
Tracking
Production Order
Manual
Usage Decision
Product
Evaluation
Results
Customer
Requirement
Quality
Results
1
2
3
4
5
6
7
Quality
Results
8
9
10
10
11
Quality Management Request & Response
(Product Releasing, Product Certification)
QOM
Transactional Data Repository
Master Data
Management
Master Data Repository
Quality
Specifications
Dimensional
Specifications
Material
Definitions
Production
Orders
Internal
Quality Specification
Order Confirmation
Material
Lots
Quality
Results
Product
Evaluation
Results
Quality
Yield
Results
Material
Movement
Results
Internal Quality
Specifications
Product
Classification
Results
QOM
Internal Request
Management
Quality Specification
Releasing
In Process Waiver
Approval
Product Classification
Product Evaluation
Non LIMS
Quality Results
Data Collection
Samples Taken
Data Collection
Quality Analysis
In Process
Waived
Orders
Test Scheduling Samples
Taken
Results
Requested
Sales
Orders
Customer
Requirement
Customer
Waived
Orders
SAP SD
SAP QM
SAP PP
Sales Order
Processing
QM Order Confirmation
Customer Waiver
Approval
Master Data Repository
Quality
Specifications
Dimensional
Specifications
Material
Definitions
Master Data
Management
Transactional Data Repository
Requested
Sales
Orders
Quality Specification
Order Confirmation
Customer
Requirement
Order Confirmation
Dimensional
Specification
Confirmation
Product
Certification
Quality Specification
Releasing
Customer
Requirement
Releasing
Dimensional
Specification
Releasing
QM Product Releasing
Production Order
Processing
Transactional Data Repository
Confirmed
Sales
Orders
Production
Orders
Confirmed
Sales
Orders
Transactional Data Repository
Confirmed
Sales
Orders
Customer
Requirement
Customer
Waived
Orders
Customer
Waived
Orders
MES Production Order Management
Transactional Data Repository
Production
Orders
Material
Lots
Product
Classification
Results
MES
Work Order
Tracking
Production Order
Manual
Usage Decision
Product
Evaluation
Results
Customer
Requirement
Quality
Results
1
2
3
4
5
6
7
Quality
Results
8
9
10
10
11
Sample Client Experience
An international steel company needed to increase through yield
and create a basis for continuous
improvement. Together we:
• Created an end-to-end process blueprint covering full application
portfolio.
• Embed control processes for
tracking performance.
• Developed a roadmap for a transformation program
(including project prioritization,
champions, sponsors, timelines, and value capture profile).
• Implemented Integrated Quality
Operations Management
Solution to increase # auto evaluations; optimize claims
investigation; reduce # 1st intent
re-classes; optimize process capability & reduce excess
material.
7
Copyright © 2011 – 2012 Accenture All rights reserved.
A consistent set of standard, end-to-end Operations Management Capabilities exist across Product/Region/Plant
… and you should manage exceptions, and not allow it to become the rule.
8
Business
Architecture
Technology Architecture
Application Architecture
Data Architecture
Common (70% of solution)
Commodity specific (20% of solution)
Site specific
Sample client experience
Copyright © 2011 – 2012 Accenture All rights reserved.
Benefits from overall process integration often outweigh best-of-breed solutions in non-distinctive capabilities
End-to-end
processes
Optimized
solution
landscape
Distinctive capabilities High Performance
Business Research
Business Process
Management
Solution
accelerators
9
Copyright © 2011 – 2012 Accenture All rights reserved.
Significant business opportunities exist to drive incremental value through extending the usage of SAP footprint …..
…. by taking and end-to-end view of Operations Management capabilities and
application landscape across ERP and MOM.
10
Plan & Schedule
Execute
Collect Data
Monitor
Performance
Analyze
Performance
Improve
Common (70% of solution)
Commodity
specific (20% of solution)
Site specific Quality Management Request & Response
(Product Releasing, Product Certification)
QOM
Transactional Data Repository
Master Data
Management
Master Data Repository
Quality
Specifications
Dimensional
Specifications
Material
Definitions
Production
Orders
Internal
Quality Specification
Order Confirmation
Material
Lots
Quality
Results
Product
Evaluation
Results
Quality
Yield
Results
Material
Movement
Results
Internal Quality
Specifications
Product
Classification
Results
QOM
Internal Request
Management
Quality Specification
Releasing
In Process Waiver
Approval
Product Classification
Product Evaluation
Non LIMS
Quality Results
Data Collection
Samples Taken
Data Collection
Quality Analysis
In Process
Waived
Orders
Test Scheduling Samples
Taken
Results
Requested
Sales
Orders
Customer
Requirement
Customer
Waived
Orders
SAP SD
SAP QM
SAP PP
Sales Order
Processing
QM Order Confirmation
Customer Waiver
Approval
Master Data Repository
Quality
Specifications
Dimensional
Specifications
Material
Definitions
Master Data
Management
Transactional Data Repository
Requested
Sales
Orders
Quality Specification
Order Confirmation
Customer
Requirement
Order Confirmation
Dimensional
Specification
Confirmation
Product
Certification
Quality Specification
Releasing
Customer
Requirement
Releasing
Dimensional
Specification
Releasing
QM Product Releasing
Production Order
Processing
Transactional Data Repository
Confirmed
Sales
Orders
Production
Orders
Confirmed
Sales
Orders
Transactional Data Repository
Confirmed
Sales
Orders
Customer
Requirement
Customer
Waived
Orders
Customer
Waived
Orders
MES Production Order Management
Transactional Data Repository
Production
Orders
Material
Lots
Product
Classification
Results
MES
Work Order
Tracking
Production Order
Manual
Usage Decision
Product
Evaluation
Results
Customer
Requirement
Quality
Results
1
2
3
4
5
6
7
Quality
Results
8
9
10
10
11
Quality Management Request & Response
(Product Releasing, Product Certification)
QOM
Transactional Data Repository
Master Data
Management
Master Data Repository
Quality
Specifications
Dimensional
Specifications
Material
Definitions
Production
Orders
Internal
Quality Specification
Order Confirmation
Material
Lots
Quality
Results
Product
Evaluation
Results
Quality
Yield
Results
Material
Movement
Results
Internal Quality
Specifications
Product
Classification
Results
QOM
Internal Request
Management
Quality Specification
Releasing
In Process Waiver
Approval
Product Classification
Product Evaluation
Non LIMS
Quality Results
Data Collection
Samples Taken
Data Collection
Quality Analysis
In Process
Waived
Orders
Test Scheduling Samples
Taken
Results
Requested
Sales
Orders
Customer
Requirement
Customer
Waived
Orders
SAP SD
SAP QM
SAP PP
Sales Order
Processing
QM Order Confirmation
Customer Waiver
Approval
Master Data Repository
Quality
Specifications
Dimensional
Specifications
Material
Definitions
Master Data
Management
Transactional Data Repository
Requested
Sales
Orders
Quality Specification
Order Confirmation
Customer
Requirement
Order Confirmation
Dimensional
Specification
Confirmation
Product
Certification
Quality Specification
Releasing
Customer
Requirement
Releasing
Dimensional
Specification
Releasing
QM Product Releasing
Production Order
Processing
Transactional Data Repository
Confirmed
Sales
Orders
Production
Orders
Confirmed
Sales
Orders
Transactional Data Repository
Confirmed
Sales
Orders
Customer
Requirement
Customer
Waived
Orders
Customer
Waived
Orders
MES Production Order Management
Transactional Data Repository
Production
Orders
Material
Lots
Product
Classification
Results
MES
Work Order
Tracking
Production Order
Manual
Usage Decision
Product
Evaluation
Results
Customer
Requirement
Quality
Results
1
2
3
4
5
6
7
Quality
Results
8
9
10
10
11
Copyright © 2011 – 2012 Accenture All rights reserved.
Maintenance and Reliability
Manufacturing Execution & Automation
(Industrial Automation)
Environment Health & Safety
Commodity
Trading &
Risk
Management
(CTRM)
Manufacturing
Supply Chain
(Planning
Scheduling &
Execution)
Integrated Value Chain Optimization
Execution Excellence
Commercial Optimization Plant Optimization
11
Solutions and services that bring together
disperse pieces of the value chain in a
collaborative environment that supports
fast and proactive decision making;
responding to the need of a highly
dynamic and volatile market.
Solutions and services to help
companies managing their plants
improving uptime of plant and
equipment, increasing operational
performance and ensuring compliance
with environment, health and safety
regulations.
Not only have we “wrote the book(s)” but we have significant experience in delivering results for our clients in Operations.