Global Engineering Change Management using SAP Records Management Andreas Voß, Pierburg GmbH ivip Symposium, 25. April 2007, Wolfsburg
Table of Content Agenda 1. Pierburg GmbH The Company 2. Initial Situation and Requirements 3. Solution in Detail 4. Next Steps 2
1. Pierburg GmbH The Company 1. Pierburg GmbH The Company 3
1. Pierburg GmbH The Company Rheinmetall Group Rheinmetall AG Revenue 2005: 3.400 Mill., Employees: 18.500 Rheinmetall Defense Leading Supplier for Engine Components and Systems Leading European Defense Company for Military Technology Revenue: 2.000 Mill. Employees: 11.700 Revenue: 1.400 Mill. Employees: 6.800 4
1. Pierburg GmbH The Company Structure of Kolbenschmidt-Pierburg Group Kolbenschmidt Pierburg AG Revenue 2005: 2.0 Bill., Employess: 11.700 Pierburg KS Piston KS Slide Bearing KS Aluminum Technology Engine Service Revenue: 903 Mill. Employees: 3.483 Revenue : 638 Mill. Employees : 5.779 Revenue : 171 Mill Employees : 1.015 Revenue : 210 Mill. Employees : 1.007 Revenue : 160 Mill. Employees : 375 5
1. Pierburg GmbH The Company Worldwide Locations Spain: Abadiano France: Thionville Germany Neuss Germany: Nettetal Germany: Berlin Germany: Hartha USA: Fountain Inn, SC Brasil: Nova Odessa Italy: Livorno Italy: Lanciano Czech: Ústí nad Labem China: Shanghai 6
1. Pierburg GmbH The Company Development Locations Europe Neuss, Central Engineering Center Berlin Hartha Thionville Livorno 7
1. Pierburg GmbH The Company Pierburg Information Technology ERP Central, global SAP-System SAP R/3 4.6 C Automotive (CO, FI, MM, WM, PP, QM, PM, SD, PS, DMS) SAP ERP 5.0 Human Resources (HR) (PM, PY, PT, OM) SAP Advanced Planer & Optimizer (APO) (DS, DP) SAP Records Management (RM) IT-Outsourcing CAD CATIA UNIGRAPHICS Pro/E Ideas PLM SMARTEAM SAP Mail + Portal Lotus Notes/Domino SAP Enterprise Portal IBM Mittelstand Systeme GmbH 8
2. Initial Situation and Requirements 2. Initial Situation and Requirements 9
2. Initial Situation and Requirements Initial Situation IT Tools Lotus Notes based tool for change management No integration with master data in SAP R/3 Material master Bill of material Document Info Record Change master, etc. No integration to transaction data (Stock, etc.) No Integration with various functions (e.g. Where-used-list) Inflexible Workflows 10
2. Initial Situation and Requirements Forwarding of Information (Costing, Change Notification,...) as Excel Attachment TI = Teileindex S = Seite SY = Erstellungssystem W = in w eiteren Verw endungen PW = Produktionsw erk ZI = Zeichenindex 3D = 3-D Modell N = Nacharbeiten T/B = Teil / Blatt FO = Format A / D = Archiv. / Dokumentationspflicht V = Verschrotten L = Lieferanten geb. DA = Dokumentenart AGS = Änderungsgrundschlüssel Techn. Freigabe: Pierburg Zeile 1 2 3 4 5 6 7 8 X Kunde KE DURCHGEFÜHRT JA NEIN EMPB Freigabemuster v. Lieferant X X JA NEIN JA NEIN Status Material-Nr. TI PW L Werkstoff A N Änderungsbeschreibung Verw endung Benennung Alte Mat.-Nr. Dokument-Nr. T/B S ZI FO DA SY 3D CAD-KD-Umgebung A/D W N V 2.04434.06.0 - E S - P-PB ENAC-AlSi12Cu1(Fe)df DINEN1706 GEHAEUSE D-2 04434 000 01-06 A0 PZD C X Pierburg - 3.04434.06.0 - E S - P-PB siehe Rohteil GEHAEUSE D-3 04434 000 01-06 A1 PZD C X Pierburg - - - - - P-PB - REGELKLAPPE D-6 01062 050 01-11 A1 PZD C X Pierburg - 7.01062.05.0 11 S S - P-PB - STÜCKLISTE NR Produkt-Nr. NR 1 7.01062.05.0 5 2 6 3 7 Änderungsanweisung (AEA) EMPB Freigabemuster / Ergänzungsmusterung an Kunde - - - - PZD S - SAP - 2.04434.05.0 3.04434.05.0 Produkt-Nr. Verteiler Änderungsgrund / Bemerkung Konstr.Gr.: S-ZP / P-ZL2 PSP-Element-Nr.: A-000065-01-S2-02 Bearbeiter: Witta P-ZB / P-ZS2 Änderung der Fase am Gehäuse D-3 04434 000 Datum: 06.04.2005 P-ZC1/P-EZL2 von 0,8 x 45 grad in 0,4 x 45 grad und Kantenbruch 0,15 mm hinzu genehmigt: Gläßer P-PBL 11/12 Änderungsnummer 4 8 AGS EINSATZTERMIN :13.05.05 Produkt: DKS P-PBF 11/2/3 7 526344 12 Typ: EDR-Di P-PBA 11/12 - - siehe Zeichnung + Stückliste X siehe Zeichnung + Stückliste Kostenübernahme: in Pierburg X Kunde Lieferant siehe Zeichnung Einlauf Auslauf Werkzeug MEK /% Fertigung SKD Bemerkung / Material-Nr. ZI Benennung Material-Nr. ZI ------------------ Neu siehe Anlage geplanter Änderungseinsatz Dok ument-nr. Dokument-Nr. Investition Alt KST ± TE/% ± /% Zeile 1 2 3 4 5 6 2.04434.06.0 D-2 04434 000 3.04434.06.0 D-3 04434 000 GEHAEUSE 06 GEHAEUSE 06 P-EZL21 Kostenermittlung (KE) Menge 2.04434.05.0 EF 1 05 D-2 04434 00 EF 3.04343.05.0 EF 1 05 D-3 04434 000 EF Anreger: Pierburg Gehaeuse als Gussteil und Bearbeitung ist Eigenfertigung. Kunde: DAEWOO P-PBQ 1/2/12 8 Blatt 1 von 1 NR Erzeugnis-Nr NR Erzeugnis-Nr NR Erzeugnis-Nr Abteilung Name Datum 1 7.01062.05.0 5 9 2 6 10 3 7 11 4 8 12 Erzeugnis: DKS ERS.F.KE-NR. Art der Änderung / Bemerkung PSP-Element-Nr.: A-000065-01-S2-02 Änderung der Fase am Gehäuse D-3 04434 000 von 0,8 x 45 grad in 0,4 x 45 grad und Kantenbruch 0,15 mm hinzu K.GR: P-EZL 21 BEARB.: Exner GEPR.: Gläßer DATUM: 04.04.05 KE-NR.: 526344 Typ: EDR-Di Kunde: DAEWOO Blatt 1 von 1 Bl. Änderungsanweisung Genehmigung Ja Nein Vertrieb / Controlling Unterschrift: Datum: 11
2. Initial Situation and Requirements Requirement for a New Solution System based management of Change Forms change request, change order, etc. Integration of master and transaction Data Flexible workflow control Management of related documents Extensive reporting Mail integration with Lotus Notes Support of international locations SAP based solution, since SAP is strategic platform for Pierburg 12
3. Solution in Detail 13
Phases of Engineering Change Process Responsibility: BU Responsibility: Plant ECN (Engineering Change Notification) ECR (Engineering Change Request) ECI (Engineering Change Implementation) MCI (Manufacturing Change Implementation) M1 Change Request issued M2 ECN release M3 ECR released M4 ECI completed M5 Change completed 14
Phases of Engineering Change Process Responsibility: BU Responsibility: Plant ECN (Engineering Change Notification) ECR (Engineering Change Request) ECI (Engineering Change Implementation) MCI (Manufacturing Change Implementation) M1 Change Request issued M2 ECN release M3 ECR released M4 ECI completed M5 Change completed 15
Basic Data Pierburg specific data fields 16
Basic Data Integration of Original SAP data fields -> Input help -> Data validation 17
Collect Affected Parts ATO-Cockpit (AusTauschObjekt) -> Input material numbers to be exchanged -> Input help, data validation 18
Plants 1. Read plant specific records of materials 2. Display in ATOC 3. Automat. read of virtual attributes 19
Integrated Where-Used-List 1. Call Where-Used-List from ATOC 2. Store Where-Used-List in VN Cockpit Original Direct Predecessor Usage 20
Integrated Where-Used-List 3. Evaluate Usage w.r.t. change relevance 21
Integrated Where-Used-List 4. Transfer of affected materials into ATOC (change scope) 22
Detailed Information (Customer, Stock,...) 23
Documents for Material (e.g. Drawing) 24
Team Definition / Distribution List 25
Release Change Request 26
Process Route Initiate follow-on tasks 27
Information im Mailsystem Drill-down to change case 28
Phases of Engineering Change Process Responsibility: BU Responsibility: Plant ECN (Engineering Change Notification) ECR (Engineering Change Request) ECI (Engineering Change Implementation) MCI (Manufacturing Change Implementation) M1 Change Request issued M2 ECN release M3 ECR released M4 ECI completed M5 Change completed 29
Complete Process Route Extension of the process route by authorized user -> sequential -> parallel -> template or single step -> directly to user or roles from the project team 30
Compile Information from Departments (eval. documents, costs,...) Status dependent Layout: here: Costing 31
Create Attachments 32
Change/Display Attachments 33
Phases of Engineering Change Process Responsibility: BU Responsibility: Plant ECN (Engineering Change Notification) ECR (Engineering Change Request) ECI (Engineering Change Implementation) MCI (Manufacturing Change Implementation) M1 Change Request issued M2 ECN release M3 ECR released M4 ECI completed M5 Change completed 34
Creation of Change Master Record 35
Definition of Change Package 36
Maintenance of Material Master 37
Maintenance of Material Master 38
Phases of Engineering Change Process Responsibility: BU Responsibility: Plant ECN (Engineering Change Notification) ECR (Engineering Change Request) ECI (Engineering Change Implementation) MCI (Manufacturing Change Implementation) M1 Change Request issued M2 ECN release M3 ECR released M4 ECI completed M5 Change completed 39
Same Technical Procedure as in Previous Phases Extension of Process Routes (via single items or templates) Input of Data in ATOC Drill-Down to Maintenance Transactions Documentation of Change Status by Advancement of Status Control Net 40
4. Next Steps 4. Next Steps 41
4. Next Steps Goal 2007 ff.: Implementation of SAP RM as an Integration Platform for... Market Strategy Pre-D Selection Process Pre-D Advance Development PDP Product Development Technology ECM Eng. Change Management LiP License Management PTP Production Transfer??? 42
4. Next Steps Solution Scenarios The presented solution is a Pierburg specific project solution ILC PROSTEP offers components as a product Further information is with ILC PROSTEP 43
End Questions? Contact: Andreas Voß Mail: andreas.voss@pierburg.com 44