WIXLIB

IndustrialIT ECSEnterprise Connectivity SolutionsImproving the total cost of ownership of your ERP System

Realize the true value of your ERPinvestment with minimal integration effort“Less than 1% of respondents indicated thatmanufacturing data is automatically integratedwith ERP with no manual intervention.”Managing Automation and AMR,September 2005 Customer SurveyThe connected enterprise: from thebusiness system to the plant floorABB’s Industrial IT ECS Enterprise ConnectivitySolutions bridge the vertical integration gap betweenBusiness and Manufacturing systems, deliveringsignificant new opportunities to increase productivity.As with most major ERP suppliers, SAP hasintroduced its Web Service integration platform.Because of the complexity of ERP systems, SAP,and other players have had to adopt multiple,different strategies to integrate business andmanufacturing. Where the manufacturing systemrequirements are relatively light, with productionorders being transferred from the businesssystem and production responses being set fromthe shop floor, SAP positions the xApp Manufacturing Integration and Intelligence (xMII) as theinterface of choice. In more complex scenarios,where interfacing to multiple modules inside ofSAP is more likely, SAP positions the eXchangeInfrastructure (XI) as the most suitable interface.SAP, along with other ERP vendors has adoptedthe ISA-95 Enterprise to Manufacturing Integration standard for Process Industry manufacturers.While this facilitates the exchange of informationin a common format (figures 1 and 3), challengesremain. ABB addresses these challenges byenhancing the communication between SAPand manufacturing systems, as shown infigures 2 and 4.figure [1] SAP View-Simple Facilitiesfigure [2] ABB View-Simple FacilitiesYou’ve invested a great deal in your ERP system .in terms of time and money. While you may be effectively managing your business systems, you maynot be using your ERP system to its full potential. Ascompanies strive to become more adaptive in theglobal marketplace, the integration between plantoperations and enterprise business applicationsbrings major opportunities to improve productivity,flexibility, quality control and to reduce the order tocash cycle. Realizing these opportunities ultimatelyimproves the return of your ERP system investment.Even with ERP companies adopting standards likeWeb services and ISA-95, most manufacturers havemultiple systems of varying vintages. The challengebecomes obtaining the required information whilepreserving the investment in the existing systems.SAP ERP MANUFACTURINGUPLOADCONFIRMATIONDOWNLOADORDERSAP ERP MANUFACTURINGProduction, Quality,Maintenance, Inventory InformationSAP xMIISAP xMIIISA-95COMPLIANTMESSAGINGECSISA 95PRODUCTIONSCHEDULEISA 95PRODUCTIONPERFORMANCESHOP FLOOR AUTOMATION& CONTROL SYSTEMS[ ]Industrial IT ECS SolutionsISA 95 Production, Quality,Maintenance, Inventory InformationSHOP FLOOR AUTOMATION& CONTROL SYSTEMS

Make the Connectionat lower cost, with fewer interfacesApart from having to deal with the significantconceptual differences between ERP andAutomation systems, perhaps one of the mostprevalent challenges is dealing with the enormous installed base that exists in manufacturingtoday. These systems, few of which are ISA-95compliant, have been viewed as cost prohibitiveto interface to business systems. ABB’s ECSEnterprise Connectivity Solutions fill this gapand provides a unified framework for dealingwith transactional and event driven systems ina common environment, as well as providing acomplete mapping between ISA-95 messagesreceived from xMII or XI and the requirementsof the plant level systems, whether they arestandards compatible (ISA-95, ISA-88), OPCconnections, Open Database Connections(ODBC) or connecting to proprietary interfaces.Additionally, with ECS, it isn’t required that theSAP system be upgraded to NetWeaver or toimplement xMII. ECS has been designed toconnect to legacy SAP R/3 systems via moretraditional SAP interfaces such as BAPI, RFCand IDOC and to a large number of other ERPsystems through standard ECS interfaces. ECSEnterprise Connectivity Solutions providea robust, easy to implement solution thatis designed to fill the gaps left by ERPinterconnect solutions.figure [3] SAP View-Complex Facilitiesfigure [4] ABB View-Complex FacilitiesSAP ERP MANUFACTURINGSAP ERP MANUFACTURINGSubsystemSubsystem[1][2]SHOP FLOOR AUTOMATION& CONTROL SYSTEMSERP SHOPFLOORERP SHOPFLOORSAP NDOWNLOADORDERSAP XIMES/CPMMES/CPMECSSHOP FLOOR AUTOMATION& CONTROL SYSTEMS[ ]ABB Inc.

Manage your businessmore effectivelyReduced Total Cost of Ownership (TCO)ECS reduces the Total Cost of Ownership (TCO) forintegration of ERP and Plant systems by using astandard product for all vertical integrations, ratherthan of custom developed Point to Point solutions.For example, a company with 20 production sitesmay need at least 50 interfaces to SAP components. SAP has stated that programming andmaintenance can cost around 20,000 per interface point; the total costs over a five year periodare roughly 5 million. With ECS, only one standardinterface to SAP is required.Improved predictabilityECS enables inventory reductions by linking thereal time information about production and materialconsumption with ERP stock and material management tools. The ECS optimizes the production planby producing the right products or intermediates atthe right time, in the needed quantity.Enterprise Connectivity Solutions also managedemand variations and increases SupplyChain flexibility through real time integrationof manufacturing units with ERP productionplanning and work order management.This business wide supervision, which providesnotification of delays, forecasted material shortage,etc., helps to prevent bottlenecks, saving you timeand money.Lower project riskECS has a standardized SAP certified interface thatuses ISA-95, SAP’s supported standard for verticalintegration in the manufacturing industries. Usingthese standard certified components dramaticallyreduces project risk. This also lowers validationefforts for regulated industries.Built in functions for failover support, messagebuffering and data validation ensure robust operation.Data is secure; if the connection is down or ERPsystem is offline for maintenance, no data will be lost.No need to rip and replace – usewhat you already haveECS works with your installed plant systems andhelps you get the most value out of the investmentsyou’ve already made. The integration capability ofthe System 800xA architecture (on which ECS isbuilt) allows the data to reside in its original system,eliminating the need to replicate it into anotherhistorian, reducing cost and improving reliability.ECS lowersDOWNLOADthe total cost of ownership by simplifying multiple connections into one standard interface.ORDERBUSINESS SYSTEMSBUSINESS SOLUTIONERPSCMCRMERPCRMSCMSAP NetWeaverINTEGRATEDCOMPOSITEAPPLICATIONSE BUSINESSLEGACYPLANT FLOOR SYSTEMS[ ]Industrial IT ECS SolutionsECSENTERPRISEINTERFACEPLANTINTERFACEABB & THIRD PARTY CONTROLSYSTEMS, HISTORIANS & CPM

A single point interfacefor integrationsECS provides a streamlined, single point interface that is suitable for enterprises of all levels ofcomplexity. Here are a few examples of how it works:In batch production, the Control Recipe is stored inthe SAP Production Planning module for ProcessIndustries. ECS downloads the control recipe andpopulates the parameters in ABB’s 800xA BatchManagement. During and after the batch execution,status updates and production information is sentto SAP from ABB’s 800xA Information Manager. Thisis an ideal solution for pharmaceutical, chemicaland food and beverage industries.At April Indonesia, a large pulp and paper company,ECS is used for integration between SAP and ABB’sCollaborative Production Management (CPM)system in a fine paper mill. This large integrationproject has three different modules from SAP (SP,PP, PM); with up to 17,000 messages exchangedbetween SAP and the ABB CPM every day. TheABB CPM sends status updates to SAP duringproduction and provides a production confirmationonce production is ready; then SAP creates thecustomer invoice. SAP also gets information fromthe ABB CPM to make a Capability and AvailabilityTo Promise check.figure [5] ECS coverage over multiple industries.SAP ERP D SHOPFLOOR DATASAP xMII(Dashboard & KPIMonitoring)SAP XIECSABB Enterprise Connectivity Solutions (ECS)Cement &MineralsMetalsKnowledgeManagerCPM @ MetalsPulp & PaperChemicals,Pharma, F&BOil & GasOffshoreOil & GasOnshoreCPM forPaper800xA BatchPIMS apps.for O&GSCADAVision-95CPMDCS800xAABB and third party control systems and historiansABB also uses ECS in its ownproduction plant for Circuit Breakers inDalmine Italy. In Dalmine, ECS is usedwith SAP to integrate manufacturing;it has been in operation since 2004[ ]ABB Inc.

Standard built-in toolsmake the connection possibleThe ECS Core Platform provides the basic execution functionality and generic connectivityneeded to support configuration and servicing of connectors. It is fully scalable and includesevent handling, transaction handling, error and application logging support and failoversupport. It includes an array of tools to design, configure and administer the Solution:Process Definition Manager provides processdefinition, development environment, support fordata mapping, event management and deployment. The support for data mapping enables easymaintenance of mapping definitions between thedata in different applications. Event managementprovides real-time status monitoring of events asthey are being executed.ECS Connectors are ready-to-use enterpriseservices that provide connectivity to a wide rangeof packaged applications.ECS connects to and integrates with any SAP R/3system on the BAPI, RFC or IDoc level. It usesfull SAP transactional RFC (Remote Function Call)support to enable high and simple configurabilitywhile it automatically transfers data to or from thesystem (figure 6). O PC Connector allows real-time applications todirectly connect to business systems or Portals. T CP/IP Connector provides integration withall TCP/IP based applications, such as Webservers and mail servers.ERPSystemRDBMSDatabaseWorkflowEngineABB CPMfigure [6]800xAChoice BNETWEAVERWEB SERVICEIDocBAPIIndustrial IT ECS SolutionsXIxMIIISA-95Both options are available and ABB can usewhichever one works best in a given situation.WEB SERVICE[ ]3rd PartyHistorianfigure [7]SAP R/3RFC3rd PartyControlsChoice A W eb Services Connector provides integrationwith enhanced SOA applications, including SAPNetWeaver (figure 7). Database Connector is a pre-built componentthat can connect with RDBMS Databases.ECSECSECS800xA800xAISA-95B2MML