To stay competitive in production consulting, among other things, you should know how to optimize manufacturing processes and keep up with new technologies. In this case, simulation modeling is an effective solution for exploring and testing optimization options.
In this blog post, we go through the PwC experience of integrating simulation modeling with the SAP module for production optimization.
Contents:
- What is the SAP Digital Manufacturing module?
- The power of SAP and model integration for production optimization
- PwC case of SAP and simulation model connection
- Challenges and PwC tips to overcome them
- Future focus: optimizing manufacturing with digital twins
What is the SAP Digital Manufacturing module?
SAP Digital Manufacturing is a module within the SAP ERP (Enterprise Resource Planning) system. It primarily connects physical production setups such as industrial machinery and factory floors, facilitating real-time interactions with these assets and environments.
The module is vital for process optimization in manufacturing. You can use it to collect real-time data from factory floor sensors, providing insights into production status and machine performance.
The module analyzes data trends to foresee maintenance needs, reducing unexpected downtimes. It also helps plan production in detail, making sure you use the resources in the best way possible.
You can easily connect it with other systems, such as AnyLogic simulation models, and find smart solutions for process optimization in manufacturing. This helps with decision-making and improves production by making it easier to see what's happening.
The power of SAP and model integration for production optimization
The following features of SAP and simulation models offer exciting possibilities for manufacturers:
- Real-time monitoring: Access to real-time data from production setups empowers manufacturers to monitor their operations closely.
- Predictive maintenance: Manufacturers can foresee and prevent downtime or disruptions by simulating diverse scenarios and scrutinizing potential issues.
- Optimization opportunities: Simulating a production environment helps identify bottlenecks and inefficiencies, enabling proactive adjustments.
- Testing and planning: Simulation models provide a sandbox environment for testing and improving processes before changing the physical world.
Integrating SAP and simulation models brings together the best of both worlds, offering a powerful solution for manufacturing optimization.
PwC case of SAP and simulation model connection
At the AnyLogic Conference 2023, Hannah Moran and Hannah Shapiro presented a PwC case of integrating SAP with the AnyLogic simulation model. This project had two main parts: the technical side and the project's relevance to PwC consulting teams and their clients.
The main concept of combining SAP and AnyLogic is to visualize manufacturing processes. Managers might find it challenging to handle all the data in the SAP module, understand the source of the numbers, and see how they impact production. The SAP Digital Manufacturing module isn't clearly arranged, but everything becomes clear and straightforward when you add AnyLogic simulation models.
The PwC team used a demo model of a solar panel manufacturing floor, which sped up their simulation development.
This solar panel production line has 15 stations, all programmed into the SAP module. It updates in real time and gathers information from every station. It plans and gives orders directly to the shop floor through API calls.
In the project, engineers used the simulation model to test parameters before adding them to the production flow. The team wrote custom Java code to handle complex features such as API integration and multithreading. This helped PwC effectively tackle engineering challenges. PwC demonstrated the use of simulation models for process optimization in manufacturing by integrating AnyLogic with SAP.
For more examples of SAP working with AnyLogic, read the blog post "An Approach to an Operational Simulation." It highlights a real-world case study about how a company uses SAP for its operational tasks.
Challenges and PwC tips to overcome them
When integrating SAP with simulation models, you might face several technical challenges. These include:
- API Integration: Linking the simulation model to SAP requires good API integration. This can be tricky because of timing problems and error codes.
Solution: Add checks within the API class to ensure API calls finish successfully. - Multithreading: The model shows a visible delay when API calls are running.
Solution: Use multithreading to reduce delays when managing several API calls at the same time. - Order in SAP: SAP settings should match the layout of the AnyLogic process flow.
Solution: Make sure the SAP system receives the API call before moving the item to the next station. - Corporate Security: The model must align with corporate security rules and SAP factory authentication.
Solution: Create a new bearer token every hour for API calls.
Despite these challenges, PwC enabled seamless data flow between the simulation model and SAP. Using the tips tested in this project, you can implement the technology and achieve results.
Future focus: optimizing manufacturing with digital twins
The successful integration of SAP and the simulation model opens doors for new ideas in manufacturing optimization. In the future, PwC could use this project to predict production tendencies, better plan resources, have seamless communication between the simulation model and SAP, and track real-time data. This project could serve as a foundation for developing a fully-featured manufacturing digital twin.
The project results highlight the ease and importance of integrating new technologies for process optimization in manufacturing. These advancements help companies improve their operations and give them a competitive edge.
