How to hookup SAP PP-PI to the Plant

Floor using XML and S95

…in just a few weeks!

Working interface deployed at Cervecería Polar

October 2003
Caracas, Venezuela

Francisco Ferrero Alejandro Imass

Empresas Polar MPR de Venezuela S.A.

B2MML to SAP at Polar Copyright © 2004 World Batch Forum Slide 1

Primary Requirements

• Interface SAP PP-PI to the Plant Floor

– In real time
– Using open standards
– Configurable
– Implemented with COTS (Commercial Off-The-Shelf) products
– Minimum or zero custom programming.
• Comply with World Batch Forum’s B2MML, based on
ISA S95 (IEC/ISO 62264 )

B2MML to SAP at Polar Copyright © 2004 World Batch Forum Slide 2

Detailed Requirements

• Integrate all production areas of all the plants

• Deliver process orders to the plant floor on-line
• Report actual production in real time
• Synchronize silos stock with SAP MM
• SAP BAPI must be used if available in favor of RFC,
IDOC or any other mechanism

B2MML to SAP at Polar Copyright © 2004 World Batch Forum Slide 3

 Had to choose between this…

SAP
APO PP PP-PI PM QM

Scheduler
S-88 Historian
Fuzzy Logic
Batch EMI
SCADA
Systems

PLC Area 1 PLC Area 2 PLC Area 3 PLC Area 4

B2MML to SAP at Polar Copyright © 2004 World Batch Forum Slide 4

 …or this!

SAP
APO PP PP-PI PM QM
SAP Bussines Conector (BC/XML)

XML
Scheduler S-88 Historian
Fuzzy Logic Batch SCADA EMI
System

OPC
PLC Area 1 PLC Area 2 PLC Area 3 PLC Area 4

B2MML to SAP at Polar Copyright © 2004 World Batch Forum Slide 5

 Why use International Standards

HTTP, XML, XSLT, ISA S95, WBF B2MML

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Why XML and HTTP?

• Because of XML’s flexibility and eXtensibility

• HTTP is simple and thoroughly proven
• XSLT was fundamental because:
– Graphical mapping is still non-standard
– Very complex data-to-structure mappings
– Proved almost impossible for BAPI XML
– Avoided obsolescence
• SAP Business Connector™ uses XML/XSLT/HTTP
• The Historian uses XML and HTTP

B2MML to SAP at Polar Copyright © 2004 World Batch Forum Slide 7

Why ISA S95 and WBF B2MML?
• S95
– Our excellent experience with S88
– Eliminated time-consuming discussions between Engineering
and IT
– Provided a clear, flexible and logical structure
– Provided a tight boundary on scope
• B2MML
– Implements ISA S95 in XML
– Can be Extended
– Includes an unbounded ANY type
• Key for SAP BAPI specifics
• It let us create “B2MML4SAP”

B2MML to SAP at Polar Copyright © 2004 World Batch Forum Slide 8

 ISA S95 - IEC/ISO 62264

S95 is a “…set of standards that defines

the interfaces between enterprise Order
activities and control activities…” Processing
Product Cost
Product
Shipping
Accounting
Admin
Production
Scheduling
Production
Schedule
Production
Defines: Performance

Product
Material and Production Inventory
Energy Control
•Boundaries Material and Energy Control Control
Inventory
•Messages
•Direction of flow
•Data structures Procurement Quality
Assurance

Maintenance
Management

Red lines and text represent the interface developed

B2MML to SAP at Polar Copyright © 2004 World Batch Forum Slide 9
 FIRST STEP

Identifying SAP BAPI and S95 Equivalence

B2MML to SAP at Polar Copyright © 2004 World Batch Forum Slide 10

BAPI and S95

SAP To download recipes PCS

BAPI
=
S95
ControlRecipe ProductionSchedule

BAPI
ProcessMessagePI.
CreateMultiple
= S95
ProductionPerformance

To report actual production

B2MML to SAP at Polar Copyright © 2004 World Batch Forum Slide 11

Transactions

• S95 defines the messages, direction and structure

but does not define protocol
• B2MML does not define transactions nor do the data
structures have status
• The PCS adapted to BAPI protocol
• To be consistent, we decided to use the same
document for all the steps of the BAPI protocol

B2MML to SAP at Polar Copyright © 2004 World Batch Forum Slide 12

BAPI Control Recipe Protocol Example

SAP BC Translates to PCS Issues

ControlRecipe.GetList B2MML ProductionSchedule

BAPI Invoke - SAP Sends SAP BC Translates to

ControlRecipe.GetListResponse B2MML ProductionSchedule

SAP BC Translates to PCS Receives List and Issues

ControlRecipe.Request B2MML ProductionSchedule

BAPI Invoke - SAP Sends SAP BC Translates to

ControlRecipe.RequestResponse B2MML ProductionSchedule

PCS Receives Final

B2MML ProductionSchedule
B2MML to SAP at Polar Copyright © 2004 World Batch Forum Slide 13
 SECOND STEP

Detailed Mapping Between

SAP PP-PI and S95

B2MML to SAP at Polar Copyright © 2004 World Batch Forum Slide 14

 Mapping
Mapping SAP
SAP PP-PI,
PP-PI, S95
S95 Production
Production Schedule,
Schedule,
S88,
S88, and
and the
the Physical
Physical Model
Model
SAP PP-PI S95 Production Schedule S88 Physical
BAPI Production Schedule
ControlRecipe.Request.Response
1..*
Process Order Production Request Control Recipe
Process
1..1 1..1 1..1
Cell
ProductSegment
Control Recipe Procedure
(S95 Segment Requirement)
1..1 1..*
1..* 1..*
Material Produced Req. 1..1
1..*

ProcessSegment
Operation Unit Procedure
1..1 (S95 Segment Requirement) 1..1
1..1 Unit
1..* Resource 1..*
1..* Equipment Requirement

OperationSegment
Phase 1..* Operation
(S95 Segment Requirement)
1..* 1..*
1..* 1..*
Process Parameter
Process Instruction Phase
Equipment
Personnel Requirement
Module
The SAP PP-PI to S88 mapping Material Consumed Req. The S95 mapping to SAP
is partially based on the works R/3 PP-PI and S88 is Control
Consumable Expected Req. Module
of G.Frey, 1998 based on our work

B2MML to SAP at Polar Copyright © 2004 World Batch Forum Slide 15

Detailed Mapping Example
(illustrative)
Highly Structured B2MML Non-structured and complex

XSLT
B2MML ProductionSchedule tables returned by SAP

Production Schedule SAP Table:

CntlRecHeader
Production Request

ProductSegment
(S95 Segment Requirement)
SAP Table:
CntlRecCharac
ProcessSegment
(S95 Segment Requirement)

SAP Table:
OperationSegment
(S95 Segment Requirement) CntlRecProcInstr
Process Parameter

Personnel Requirement SAP Table:

Material Consumed Req. CntlRecTextLines
Consumable Expected Req.

B2MML to SAP at Polar Copyright © 2004 World Batch Forum Slide 16

Hiding the Complexities of SAP BAPI

• Some of the mapping is Structure to Structure

• Most of the mapping is DATA to Structure
• This is why XSLT was fundamental.
• BAPI complexities are hidden inside the SAP BC
• The result is a SAP PP-PI that actually communicates
bidirectional in B2MML
• “We made the SAP BAPI ‘speak’ S95, instead of
traditional BAPI tables”

B2MML to SAP at Polar Copyright © 2004 World Batch Forum Slide 17

 THIRD STEP

Implement
Interface Components

B2MML to SAP at Polar Copyright © 2004 World Batch Forum Slide 18

 Macro Components – Block Diagram

S95 Production Schedule

Clear Complex
<sap:CNTL_REC_STATUS>
00001
</sap:CNTL_REC_STATUS>
<sap:TEST_FLAG>
0
</sap:TEST_FLAG>
XML
<MaterialProducedRequirement>
ActivPlant <MaterialDefinitionID> SAP
S88 125 SAP
ActivPlant Enterprise Business
PCS </MaterialDefinitionID>
PP-PI
Gateway <Description>
Descripción del MaterialSAP Connector
</Description>
<MaterialLotID> BC XSLT
BATCHNUMBER
</MaterialLotID>
Service
<sap:INSPLOT>
XML 123456789012
</sap:INSPLOT>

S95 Production Performance

B2MML to SAP at Polar Copyright © 2004 World Batch Forum Slide 19

 What the Interface actually does

B2MML to SAP at Polar Copyright © 2004 World Batch Forum Slide 20

Current Functionality

• SAP Production Orders (actually Control Recipes) are

downloaded to the ActivPlant System.
• ActivPlant propagates some information to the PLC or
S88 systems to keep track of batch numbers
• With the Control Recipe conditions are set-up for
automatic and real-time “ProductionPerformance”
reporting.
• SAP MM Silo Inventories are synchronized with Plant
Floor for correct reporting of consumed material

B2MML to SAP at Polar Copyright © 2004 World Batch Forum Slide 21

 Conclusions

B2MML to SAP at Polar Copyright © 2004 World Batch Forum Slide 22

Bottom Line

• The first complete prototype was completed in 5 weeks

– Understanding S95/B2MML
– XSLT programming
– SAP BC Configuration
• The interface was implemented during the SAP PP-PI
project!
• A smaller “one-off” interface needed over a year to
complete and was never fully reliable
• This one has been working non-stop since October
• Mission Critical: if it fails, the plant stops – business
decision

B2MML to SAP at Polar Copyright © 2004 World Batch Forum Slide 23

Next Steps

• Cervecería Polar and MPR de Venezuela will make

public this information and all XSLT code through the
WBF, so that others can contribute and further
promote these standards
• Stay updated to changes of S95 / B2MML and other
standards to continually iterate the interface and keep
it updated

B2MML to SAP at Polar Copyright © 2004 World Batch Forum Slide 24

 END

Questions?

B2MML to SAP at Polar Copyright © 2004 World Batch Forum Slide 25

Contact Information

Francisco Ferrero Alejandro Imass

Empresas Polar S.A. MPR de Venezuela S.A.
francisco.ferrero [email protected]
@empresas-polar.com P: 58-212-237-4774
P: 58-212-202-3406 F: 58-212-237-5548
F: 58-212-202-3465 C: 58-412-9986282

B2MML to SAP at Polar Copyright © 2004 World Batch Forum Slide 26

Theoretical Background

• Our PP-PI to S95 was based on the work by:

– G. Frey of Institute of Process Automation, University of
Kaiserlautern, Germany
– Th. Egger Zeneca GmbH, Schwetzingen/Plankstadt,
Germany
• Paper #27 presented at the 10th International IFIP
WG 5.2/5.3 Conference Prolamat'98 “Mapping of
SAP Recipe to a Control Recipe”
• Present knowledge on S88 systems in use at Polar

B2MML to SAP at Polar Copyright © 2004 World Batch Forum Slide 27

 ProductionShedule Request
and Response Example

SAP BC
HTTP POST

B2MML Production B2MML to BAPI ControlRecipe BAPI

ActivPlant Schedule XML XSLT Invocation
Enterprise (REQUEST)
Gateway
SAP
PP-PI
HTTP RESPONSE

B2MML Production
Schedule XML BAPI to B2MML BAPI XML
ActivPlant (RESPONSE) XSLT
XML

WebMethods Service

S88 Non-S88
Systems Systems

B2MML to SAP at Polar Copyright © 2004 World Batch Forum Slide 28

Commercial off-the-shelf Solutions

• SAP Business Connector™ is available for all SAP

clients
• ActivPlant provided XML connectivity through it’s
Enterprise Gateway™ product
• Configuring, not programming
• The only “programming” was XSLT

B2MML to SAP at Polar Copyright © 2004 World Batch Forum Slide 29