Increasing digitalization and the requirements of "Industry 4.0" pose new challenges for production planning and production control. But they also offer a number of new ways to make manufacturing more robust and efficient. This applies in particular to companies in mechanical and plant engineering who operate single or small batch production.

For single and small batch pavers it is very important that the worker has all the information he needs at the moment of production on the machine. In addition to the production documents themselves, this includes the valid parts list, the drawings in the correct version, in valid and approved form, if necessary, change documentation to the previous version and possibly test instructions or other quality documents. These documents are usually not all in the ERP system, but e.g. in a PLM system or even in the file system. So they have to be put together. If this does not happen automatically, this process is error prone and involves considerable manual labor.

This is where our PRODUCTION ORDERS+ product comes in and makes the preparation of manufacturing processes with SAP much faster and more robust thanks to the automatic compilation of drawings, production resources and equipment for production orders.

At the push of a button, production papers, production aids and drawings are compiled to a production order with PRODUCTION ORDERS+.

PRODUCTION ORDERS + takes over the production papers from SAP in the form of the SAP intermediate format OTF. All documents may be provided with stamps, e.g. the FAUF number, the date of output, or the user name of the production controller. As a result of the production order, a multi-page PDF file is created containing all production papers and documents / drawings as well as a table of contents. When printing, output is uninterrupted. If the printout is not possible on a single printer because of the available paper sizes, a sentence can be split into several printers according to drawing quantities or other metadata. It is also possible to export the complete FAUF to a folder or send it to an e-mail address so that it can be displayed directly on the screen next to the machine

As an SAP user in the manufacturing industry, you benefit from the elimination of the necessary manual activities and the associated sources of error. At the same time, individual processing is always possible despite automated processing of the production orders!

Integration

The integration of PRODUCTION ORDERS+ into the existing SAP®ERP takes place exclusively via standard interfaces. Modifications are not made, so that nothing stands in the way of a later system update. The users work exclusively in the familiar environment of the SAP GUI. PRODUCTION ORDERS + is integrated via the OPK8. The SAP user rights and authorization objects on documents are taken into account when composing the documents.

Reliability

The software offers comprehensive backup options against outages on request and is therefore ideally suited for use in mission-critical areas such as manufacturing: With the installation of backup servers, a total failure of the system can be avoided, the Watchdog module can compensate for short-term network failures and load distribution to multiple servers offers the possibility to process job peaks without any problems.

Optimal printout

With PRODUCTION ORDERS+, production orders can be distributed automatically to several printers, e.g. all papers up to size A3 (production papers and drawings) on a office printer and all papers larger than A3 on a plotter. The manual compilation is very easy thanks to an automatically created table of contents as well as the application of stamps with the FAUF-Nr. and a page number.

Automatic compilation of all required documents

With PRODUCTION ORDERS+, the materials and BOMs in the SAP system are analyzed, the validity checked, the linked drawings and documents in the correct versions determined and everything put together. The parts lists are output in files so that they can also be part of the compilation. Document types, file types, release status and authorization objects are taken into account so that it is ensured that authorized persons receive all the required information, but that non-authorized persons can not gain access to the information.

The system also offers a number of convenient ways to make the job with production orders easier and more efficient:

This includes, for example the generation of a table of contents in which all parts of the production order are listed. If there are errors, such as not released drawings, the table of contents provides a complete list of errors. The order can then first be checked and corrected before it is actually issued

Another issue is stamps: in prototype production, it can be necessary to use drawings that have not been released. These are then visibly provided via stamps with the document status. The production order number can be printed on all drawings so that the context remains clear; the issue date, the time and the editor are stamped, so that it is always understandable who has arranged the printout. Furthermore, a bar code stamp may be generated, that can be scanned near the printer to acknowledge receipt of the production order in the ERP system or to signal the start of production.

Another practical feature is the automatically generated change documentation via a multicolored graphical comparison of the current version with the previous version of the drawing, which is generated when the status changes. This is particularly interesting in the case of external or outsourced production.

Archiving and documentation

In order to be able to control at a later stage how accurately the production order has been printed out, archiving in the exact form in which it was issued (for example from a product liability point of view) is very important. This includes not only the design drawings, but all relevant documents.

With PRODUCTION ORDERS+ the complete compilation with all described documents can be saved in the form of a PDF / A-2 file. In order to be able to prove that the file has not been changed from its original form, it can be provided with an electronic signature that is no longer valid after a change and thus reveals modifications.

In addition, handwritten notes e.g. for manufacturing issues or changes in the manufacturing process can be archived. Again, an automated solution can be established by scanning the documents with annotations. The FAUF-No. can then be automatically identified with appropriate software and the file can also be attached as an attachment to the production order object.

Digital Twin

By a "digital twin" is meant a virtual model, e.g. a process, a product or a service. Coupling the virtual model with the real-world product enables analysis of data and monitoring of systems.

Our solution PRODUCTION ORDERS+ supports you on the way to the "digital twin" of a machine or plant, by automatically generating all the necessary data, for example for service or maintenance, in the instant when the production order for a machine or plant is triggered. This means that all information about the machine is available in a digital, long-term archivable and unchangeable form. PRODUCTION ORDERS+ offers significantly better data quality compared to a later, manual compilation of the files.

Additional option for mass processing of production orders

With an additional option for PRODUCTION ORDERS+, employees in the AV can search for all required production orders using the SAP transaction COHV and have them displayed in a results list. From this selection, a partial selection can now be made. With the support of the new option for PRODUCTION ORDERS+, the user interface is then displayed once for this partial selection. In the user interface, the exact parameters such as printer, scaling, stamp, etc. can be selected precisely for the selection. For example, if the manufacturing sites are different for parts of the jobs (e.g., welding, milling, etc.) they may be output on different printers at the manufacturing station.

Thereafter, the initial selection is displayed again and the employee responsible can create another subselection and then specify the processing paths in a step for this second subselection.

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