Escolar Documentos
Profissional Documentos
Cultura Documentos
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l y
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O n
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U
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P
S A P
S A P
P a
s e
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U
t
n
Material Flow System
l
e
a
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n
r
O
e
Overview
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y
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I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
I
l y
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t
O n
e
r
n
SAPSPM 2 days EWM100 3 days EWM110 5 days EWM120 5 days
r
a
e
l
Management Management Management Extended Warehouse
n
U
r
s
a
e
EWM210 3h
P
S A P
(MFS) in EWM
S A P
EWM220 2h
P a
RadioFrequency
s e
Framework (RF)
in EWM
r
U
t
Clasroom training
n
EWM230 2h
l
e
Recorded clasroom training
a
ITSMobile
r
& RadioFrequency
n
in EWM
r
O
e
n
t
l
n
y
I
I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
Agenda
What MFS Is Good For & How It Works
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l y
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t
O n
e
r
n
r
a
e
l
1. Which business needs are addressed by MFS?
n
t
U
r
s
2. EWM and MFS - How are they integrated?
a
e
P
S A P
3. What are the basic concepts of MFS?
S A P
P a
s e
r
U
t
n
6. How can it be tested?
l
e
a
r
n
O
e
n
t
l
n
y
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I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
I
l y
n
t
O n
e
Directly connect SAP to the shop floor
r
n
SAP ERP SAP ERP
r
a
Control stacker
cranes and conveyors
e
l
n
U
r
system
s
a
e
P
S A P
S A P
Have
only 1 responsible for warehouse
management and material flow system
P a
s e
r
Take
benefit of SAP system landscape for SAP MFS
U
3rd Pty.
t
n
material flow layer MFS
l
e
a
r
n
SAP PCo
Have a well integrated material flow control
r
O
e
n
Reduce license cost and maintenance fee
t
l
n
y
PLC PLC
I
I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
I
l y
n
t
O n
e
Crane2
r
n
r
Crane3
a
High rack storage bins
e
l
n
t
U
r
s
a
e
P
S A P
S A P
Crane1
P a
s e
r
U
t
n
Conveyor System
TCAR
l
Transfer Car
e
a
r
n
O
Put away Pick-HU
e
n
t
l
n
y
I
Pick Point
Full pallets
Pick-HU
Requirements – ID Point
I
l y
n
t
O n
e
Crane2 Crane
r
available?
n
r
Crane3
a
High rack storage bins
e
l
n
t
U
r
s
a
e
P
Cross load
S A P
products /
S A P
Crane1
batches to In feed
aisles conveyor
P a
s e
capacity?
r
U
t
n
Conveyor System
TCAR
l
Transfer Car
e
a
r
n
O
Put away Pick-HU
e
n
HU
t
l
n
y
warehouse
I
Requirements – Cranes
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l y
n
t
O n
e
Crane2 Task
r
interleaving!
n
r
Crane3
a
High rack storage bins
e
Task
l
n
Priorities.
t
U
r
s
a
e
P
S A P
S A P
P a
s e
r
U
t
n
Conveyor System
TCAR
l
Transfer Car
e
a
r
n
O
Put away Pick-HU
e
n
t
l
n
y
I
Pick Point
Full pallets
Pick-HU
I
l y
n
t
O n
e
Crane2
r
n
r
Crane3
a
High rack storage bins
e
l
n
t
U
r
s
a
e
P
S A P
S A P
Crane1
P a
s e
r
U
t
n
Conveyor System
TCAR
l
Transfer Car
e
a
r
n
O
Put away Pick-HU
Task priorities.
e
n
t
l
Drop point
n
y
I
I
l y
n
t
O n
e
Crane2
r
n
HU 4
r
Crane3
a
High rack storage bins
e
l
n
t
U
r
s
Make efficient use
a
e
P
of conveyor
S A P
capacity and
S A P
Crane1 HU 3
resources
P a
s e
HU 2
r
U
t
n
Conveyor System
TCAR
l
Transfer Car
e
a
r
n
O
Put away Pick-HU
e
n
t
l
n
y
I
Pick Point
Full pallets
Pick-HU
Business Scenario –
Programmable Logic Controllers (PLC)
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l y
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Crane3
t
O n
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PLC RACK3
r
n
r
a
Crane2
e
l
n
PLC RACK2
t
U
r
s
Crane1
a
e
P
S A P
PLC RACK1
S A P
P a
s e
EWM
r
U
t
n
TCAR
l
e
a
r
n
IP
PLC CONSYS1
r
O
e
n
t
l
n
y
PP
I
Clearing GI
GR
I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
Responsibilities
I
EWM
l y
n
t
• Routing to final destination: Divide HU warehouse
O n
e
task into several sub-steps according to PLC
r
n
communication points (CP).
r
a
e
l
n
U
r
s
a
e
of order, blocked)
P
S A P
• Routing to clearing in case of exceptions
S A P
P a
s e
r
U
t
PLC
n
1
Scanner
l
TCAR
e
• Real time monitoring of sensors
a
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n
O
e
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t
l
• Read scanners
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y
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Aisle 1 Aisle 2
l y
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t
O n
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EWM
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n
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a
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l
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U
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a
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P
Final
S A P
Destination
S A P
CP12
P a
s e
Intermediate CP11
r
U
Destination
t
n
1
Scanner
CP02
l
TCAR
e
CP01
a
r
n
r
O
e
n
t
l
Conveyor
n
y
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PLC
I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
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Aisle 1 Aisle 2
l y
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t
O n
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EWM
r
n
r
a
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l
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t
U
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s
a
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P
Final
S A P
Destination
S A P
CP12
Intermediate
P a
s e
Destination CP11
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U
t
1
n
Scanner
CP02
l
TCAR
e
CP01
a
r
n
r
O
e
n
t
l
Conveyor
n
y
I
PLC
I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
I
Aisle 1 Aisle 2
l y
n
t
O n
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EWM
r
n
r
a
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l
n
t
U
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s
a
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P
S A P
S A P
CP12
P a
1
s e
CP11
r
U
t
n
Scanner
CP02
l
e
TCAR CP01
a
r
n
r
O
e
n
t
l
Conveyor
n
y
I
PLC
I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
I
Aisle 1 Aisle 2
l y
n
t
O n
e
EWM
r
n
r
a
e
l
n
t
U
r
s
a
e
P
S A P
S A P
CP12
P a
s e
CP11
r
U
t
n
Scanner
CP02
l
e
TCAR CP01
a
r
n
r
O
e
n
t
l
Crane1
n
y
I
PLC
I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
I
Aisle 1 Aisle 2
l y
n
t
O n
e
EWM Final
r
Destination
n
r
a
e
l
n
t
U
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s
a
e
P
S A P
1
S A P
CP12
P a
s e
CP11
r
U
t
n
Scanner
CP02
l
e
TCAR CP01
a
r
n
r
O
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n
t
l
Crane1
n
y
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PLC
I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
I
l y
n
EWM Warehouse Tasks
t
O n
e
CP1 Step 1 CP2 Step 2 CP3 Step 3 CP4
r
n
1
r
a
Warehouse Task 1
e
l
n
2
t
Warehouse Task 2
U
r
s
a
e
Telegram 1 to PLC (Task)
P
S A P
S A P
1
Telegram 2 from PLC (Task Conf.)
3
Warehouse Task 3
P a
s e
r
Telegram 3 to PLC (Task)
U
t
n
l
e
a
r
n
1
r
O
Activation Warehouse Task 1
e
n
t
l
Telegram 5 to PLC (Task)
n
y
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I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
Business Needs
I
Automated execution of warehouse tasks (move HU)
l y
n
t
First approach:
O n
e
r
Pallets and other slow moving HU types
n
r
a
e
l
n
U
Confirm previous task (post HU to new bin)
r
1.
s
a
e
2. Create / select and communicate follow-up task**
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S A P
S A P
P a
s e
r
U
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e
a
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n
r
O
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n
t
l
n
y
* ID point (bin determination) may take longer.
I
** To reduce PLC idle time the telegram is created and sent to the PLC before the WT is written to the database.
I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
Agenda
What MFS Is Good For & How It Works
I
l y
n
t
O n
e
r
n
r
a
e
l
1. Which business needs are addressed by MFS?
n
t
U
r
s
2. EWM and MFS - How are they integrated?
a
e
P
S A P
3. What are the basic concepts of MFS?
S A P
P a
s e
r
U
t
n
6. How can it be tested?
l
e
a
r
n
O
e
n
t
l
n
y
I
I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
I
l y
n
EWM WO Queue Rsrc
t
O n
e
r
PLC relevant
n
r
HU WT
a
e
l
Rsrc
n
TELE PLC
t
U
r
s
BIN BIN
a
e
P
S A P
S A P
CP CP Channel
MFS
P a
s e
Move HU from - to
r
U
t
PLC
n
l
e
Legend
a
WO – Warehouse Order
r
n
WT – Warehouse Task
r
HU – Handling Unit
O
e
CP – Communication Point
n
t
l
n
y
CP
I
CP CP RSRC
Warehouse tasks are communicated to PLCs if they are added to PLC relevant queues.
Task communication to PLCs is invoked by queue determination rules (customizing)
I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
I
l y
n
Source Storage Bin Warehouse Task Dest. Storage Bin
t
O n
e
Bin Access
r
Activity Type Warehouse Activity
n
r
a
e
Activity
l
n
Queue determination is
t
U
customizable
r
s
a
e
P
S A P
S A P
P a
s e
r
Queue for Rsrc 01 Queue for Rsrc 02 Queue for Conv 01 Queue for Rsrc 03
U
t
n
l
e
a
r
n
O
CONV01
relevant by customizing
e
n
RSRC03
t
l
n
y
I
I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
I
l y
n
t
O n
e
r
n
r
a
e
l
n
t
U
r
s
a
e
P
S A P
S A P
P a
s e
r
U
t
Create new task CP02 – CP11
n
l
e
a
r
n
r
O
e
n
t
l
WTCO HU 1 from CP01 to CP02
n
y
I
I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
Warehouse Monitor
I
l y
n
t
O n
e
r
n
r
a
e
l
n
t
U
r
s
a
e
P
S A P
S A P
P a
s e
r
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
Customizing
I
l y
n
t
O n
e
r
n
r
a
e
l
n
t
U
r
s
a
e
P
S A P
S A P
P a
s e
r
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
I
l y
n
t
EWM Alert Monitor
O n
e
r
n
r
a
e
l
n
t
U
r
s
a
e
P
S A P
S A P
P a
s e
r
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
Detailed Analysis
I
l y
n
t
EWM Application Log
O n
e
r
n
r
a
By Date / Time
e
l
n
t
U
r
s
a
e
P
S A P
S A P
P a
s e
r
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
I
l y
n
MFS is not a separate system with an additional interface
t
O n
e
MFS uses existing EWM objects and coding and extends them by additional features for
r
n
Telegram communication
r
a
e
l
n
t
U
r
s
a
Advantage
e
P
S A P
S A P
– Physical situation for stock decisions (e.g. availability of cranes for put away or
picking strategy)
P a
s e
– Warehouse requests and stock data for routing decisions (load balancing between
r
aisles, delivery data for sorting)
U
t
n
No data synchronization required between WM and MFS layer
l
e
a
r
MFS layer comparably slim
n
r
O
Disadvantage
e
n
t
l
Runs on the same machine / database
n
y
I
I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
Agenda
What MFS Is Good For & How It Works
I
l y
n
t
O n
e
r
n
r
a
e
l
1. Which business needs are addressed by MFS?
n
t
U
r
s
2. EWM and MFS - How are they integrated?
a
e
P
S A P
3. What are the basic concepts of MFS?
S A P
P a
s e
r
U
t
n
6. How can it be tested?
l
e
a
r
n
O
e
n
t
l
n
y
I
I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
I
Aisle 1 Aisle 2 Aisle 3
l y
n
Crane2
t
Crane3
High rack storage bins
O n
e
A single HU has to go several steps:
r
Crane1
n
r
a
e
Conveyor System
TCAR Transfer Car
l
ID Point Put away Removal-HU
n
U
Pick Point
Full pallets
r
Pick-HU
s
a
e
P
S A P
S A P
P a
s e
r
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
I
l y
n
t
O n
e
r
n
r
a
e
l
Inactive task to final destination
n
LP LP
t
U
r
s
a
e
P
S A P
CP CP
S A P
Deviation
(Material flow error)
P a
s e
CP CP
r
New active task
U
t
n
l
e
Unexpected Scanner Message:
a
r
HU location is adjusted
n
O
e
n
t
l
n
y
I
I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
I
l y
n
t
Every MFS relevant conveyor location is modeled as a storage bin
O n
e
r
Physical attributes of conveyor locations are kept in the new customizing object
n
r
a
e
l
n
U
r
s
a
e
P
S A P
S A P
Capacity mode (how to consider HUs, which currently are expected to arrive or
to leave this point, regarding capacity)
Behavior in case of capacity bottleneck (create appropriate WT nevertheless or
P a
s e
not)
r
U
t
Next CP direction clearing
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
I
l y
n
t
O n
e
r
n
SAP ERP SAP ERP
r
a
e
l
Short, flat messages
n
t
U
No meta data are transmitted (no structural
r
s
a
e
P
S A P
S A P
P a
s e
r
3rd Pty. SAP MFS
U
t
MFS
n
l
e
a
r
MFS-PLC Telegrams
n
r
O
e
n
PLC PLC
t
l
n
y
I
I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
I
l y
n
Sender does not send a next message before the previous one has been acknowledged
t
O n
e
r
EWM
n
r
a
e
l
n
U
17 State Request CP13 Y N
r
s
TASK CP02 – CP03
a
e
P
RFC Acknowledge
S A P
Telegram
S A P
Telegram
No. 17 No. 923
P a
PCo
s e
Acknowledge
r
Telegram Telegram
U
t
No. 17 No. 923
n
l
e
TCP/IP
a
r
n
O
No Telegram Snd Ack
e
n
PLC 1 923 State CP13 Y N
t
l
CONF CP02 – CP03
n
924 N N
y
I
I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
I
l y
n
t
• To connect EWM with the PLCs a protocol
O n
e
converter RFC - TCP/IP is required
r
n
• This RFC adapter runs separate from SAP
r
a
e
l
n
U
r
s
a
e
sets the data to another “rail”.
P
S A P
S A P
RFC
even take any responsibility to deliver them
Windows to the receiver. And it doesn’t know anything
SAP PCo
P a
about the structure and meaning of the
s e
telegrams.
TCP/IP
r
U
t
n
in EWM and passed to the adapter during
l
e
a
startup.
r
n
O
e
n
PLC separate adapter instance per warehouse
t
l
number and PLC.
n
y
I
I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
I
l y
n
SAP PCo is restricted to
t
O n
e
Windows OS
r
n
r
a
e
l
n
U
r
s
a
e
P
S A P
S A P
P a
s e
r
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
I
l y
n
MFS telegrams may be created by concurrent work processes.
t
O n
e
To send a telegram each of these processes calls /SCWM/MFS_SEND
r
n
This function module checks if there are unconfirmed telegrams in the send buffer
r
a
e
l
n
U
r
s
process (/SCWM/MFS_RECEIVE2) retrieves the next telegram from the buffer and sends
a
e
P
it.
S A P
A background job called “telegram repetition process” is responsible to check if there is an
S A P
acknowledgment telegram outstanding for a long time (e.g. 3 sec.), and then to send it
again.
P a
s e
The background process is started automatically on PLC channel startup per warehouse
r
U
number.
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
Scalability
I
Several channels per PLC possible.
l y
n
Channels are working parallel.
t
O n
e
r
n
r
PLC 1 PLC 2
a
e
l
n
U
channel are transmitted
r
s
a
e
sequentially.
P
S A P
S A P
P a
data processing are
s e
decoupled by the
r
U
t
database.
n
l
e
a
r
n
O
channel are processed Module Module Module Module
e
n
t
sequentially.
l
n
y
Follow-up events are
I
triggered asynchronously.
Main influence to the performance:
Number of work processes.
I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
I
Internal Telegram Structure (Standard)
l y
n
t
O n
Internal
e
r
processing
n
r
a
e
Mapping by
l
n
field name
t
U
External
r
s
communication
a
e
P
S A P
S A P
P a
External Telegram Structure
s e
r
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
I
l y
n
t
O n
e
r
n
r
a
e
l
n
t
U
r
s
a
e
P
S A P
S A P
P a
s e
r
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
I
ABAP coding – standard or custom
l y
MFS customizing
n
t
O n
e
r
n
r
a
e
l
n
t
U
r
s
a
e
10 ZBD_AOUT_PROCESSING
P
S A P
S A P
P a
s e
r
U
t
Customer Name Space
n
l
AOUT 10
e
ZBD_AOUT_PROCESSING
a
r
•Make some extra work
n
O
e
n
WTCO HU 1 HB01-02-07-04
t
AOUT
l
n
y
PLC telegram
I
I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
I
l y
n
EWM
t
O n
e
r
n
r
a
e
l
n
t
U
Type Meaning Type Meaning
r
s
a
e
P
S A P
S A P
P a
LF Life Check Telegram LF Life Check Telegram
s e
r
U
t
SE Synchronization End
n
l
e
a
r
Identifiers customizable
n
r
O
e
n
t
l
n
PLC
y
I
I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
I
l y
n
t
Assign telegram type identifiers to
O n
e
predefined telegram categories
r
n
r
a
e
l
telegram structures
n
t
U
r
s
a
e
P
S A P
S A P
P a
s e
r
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
I
Layout-oriented storage control
l y
n
t
Telegrams, not Idocs
O n
e
Minimal technical scope “out sourced” to external communication layer (RFC adapter)
r
n
r
a
e
l
n
U
r
s
a
e
P
S A P
S A P
P a
Resource state communication (availability, capacity)
s e
r
Scanners
U
t
n
Communication startup
l
e
a
r
n
r
O
e
n
t
l
n
y
I
*Example MFS-PLC interface description based on these functions is available (sufficient for simple warehouses)
I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
Agenda
What MFS Is Good For & How It Works
I
l y
n
t
O n
e
r
n
r
a
e
l
1. Which business needs are addressed by MFS?
n
t
U
r
s
2. EWM and MFS - How are they integrated?
a
e
P
S A P
3. What are the basic concepts of MFS?
S A P
P a
s e
r
U
t
n
6. How can it be tested?
l
e
a
r
n
O
e
n
t
l
n
y
I
I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
Kinds of Equipments
I
Conveyors
l y
n
Pallet conveyors
t
O n
e
Case conveyors – depending on performance requirements
r
n
Scanners at conveyors
r
a
e
l
Conveyor integrated stretchers
n
U
r
s
HU sorters – depending on performance requirements
a
e
P
Resources
S A P
S A P
P a
Automated guided vehicles (AGVs) – as subsystem only (executes HU WTs, controls its vehicles)
s e
r
Picking systems
U
t
HU Pick robots – may be by EWM-WCU IDOC interface
n
l
e
HU storing systems (e.g. paternoster: Presents requested HU‟s at an operator port) - if they include the
a
r
n
picking user transaction: Same as picking robots. If not – project will come (Autostore in Norway).
r
O
Pick to light / pick by light – as subsystem including pick user transaction only
e
n
t
l
Pick by voice – RF (not MFS)
n
y
I
Packing systems
HU packing robots – task from to, but without detailed packing instruction
I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
I
l y
n
t
O n
e
r
First approach:
n
r
a
e
l
telegram interface
n
t
U
Order handling systems – communicate warehouse orders via EWM-WCU IDOC
r
s
a
e
interface
P
S A P
S A P
P a
s e
r
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
Agenda
What MFS Is Good For & How It Works
I
l y
n
t
O n
e
r
n
r
a
e
l
1. Which business needs are addressed by MFS?
n
t
U
r
s
2. EWM and MFS - How are they integrated?
a
e
P
S A P
3. What are the basic concepts of MFS?
S A P
P a
s e
r
U
t
n
6. How can it be tested?
l
e
a
r
n
O
e
n
t
l
n
y
I
I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
I
l y
n
1. Define telegram structure
t
O n
e
r
2. Define interface type
n
r
a
e
l
n
t
U
r
4. Define PLC
s
a
e
P
S A P
S A P
6. Define error codes (to be sent to PLC) and EWM exceptions (to be raised by PLC error codes)
P a
7. Create a RFC destination
s e
r
U
t
8. Maintain PLC: Assign RFC destination
n
l
e
a
r
n
r
O
10. Configure RFC adapter
e
n
t
l
n
y
I
I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
I
l y
n
1. Define warehouse layout (storage type, storage bins, communication points)
t
O n
e
2. Define layout oriented storage control
r
n
r
a
3. Setup queues and queue determination
e
l
n
t
U
4. Setup task communication with PLCs
r
s
a
e
P
S A P
S A P
P a
7. Setup material flow triggers
s e
r
8. Deal with scanners
U
t
n
l
e
9. Introduce an automated identification point
a
r
n
r
O
e
n
t
l
n
y
I
I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
I
1. Connect a transfer car
l y
n
t
1. Define a queue
O n
e
2. Setup queue determination criteria
r
n
3. Define a resource type
r
a
e
l
4. Create a resource
n
t
U
r
s
2. Connect an automated high bay storage
a
e
P
S A P
S A P
P a
4. Define WT queues and queue determination criteria
s e
r
U
t
6. Control interleaving (dual cycle movement for rack feeders)
n
l
e
a
r
n
O
e
n
t
l
1. Full pallet removal
n
y
I
2. Picking
I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
Agenda
What MFS Is Good For & How It Works
I
l y
n
t
O n
e
r
n
r
a
e
l
1. Which business needs are addressed by MFS?
n
t
U
r
s
2. EWM and MFS - How are they integrated?
a
e
P
S A P
3. What are the basic concepts of MFS?
S A P
P a
s e
r
U
t
n
6. How can it be tested?
l
e
a
r
n
O
e
n
t
l
n
y
I
I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
I
With automated equipment three layers have to be kept in sync:
l y
n
t
1. EWM/MFS
O n
e
r
2. PLC
n
r
a
3. Physics
e
l
n
U
r
s
Different parties have to wait for each other (especially in case of errors)
a
e
P
S A P
S A P
P a
s e
r
Switch PLC from current WCS to EWM and back for testing
U
t
n
Don‟t change physical situation for the current WCS by moving HU‟s with EWM.
l
e
a
r
n
r
O
e
n
t
l
n
y
Urgent need for a chance to test without physical equipment.
I
I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
I
• Emulates material flow and PCL interface.
l y
n
Test Production
t
• Allows test without real warehouse equipment.
O n
Environment Environment
e
r
• Allows performance test.
n
r
a
e
l
n
• Allows to test the rest of EWM without being connected SAP ERP SAP ERP
t
U
to the real PLCs.
r
s
a
e
P
S A P
S A P
P a
s e
r
U
t
RFC-Adapter RFC-Adapter
n
l
e
a
r
PLC
n
r
O
e
n
t
PLC
l
n
y
Emulation
I
I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
I
l y
n
t
Scanner 01SC0001Goods Receipt
O n
e
r
n
r
a
e
l
n
U
Check HU OK? No Set HU exception
(height / weight)
r
HU moved to
s
EWM
e
P
Yes
S A P
No
Teletype 51 Teletype 51 HU has exception
No Set HU exception DAS
S A P
Teletype 04
P a
HU 12345678 Teletype 11
s e
r
PLC
U
t
n
l
e
height, barcode
a
r
n
r
O
e
Material Flow
n
t
l
n
Scale Scanner
Height detector
y
01SC0001 HU
I
I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
I
l y
n
t
O n
e
r
n
r
a
e
l
n
t
U
r
s
a
e
P
S A P
S A P
P a
s e
r
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
I
l y
n
t
O n
e
r
Emulation is a software
n
r
a
implementation test tool.
e
l
n
SAP EWM
t
U
r
s
a
SAP MFS
e
P
S A P
S A P
P a
s e
r
Simulation (e.g. Automod)
U
t
Emulation
n
l
e
Runs stand alone
a
r
(no connection to a host system). Runs connected to WMS.
n
r
O
Simulates material flow.
e
n
t
l
Focus Focus
n
y
I
I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
Lesson 7 – Test
I
PLC emulation as implementation test tool is crucial
l y
n
t
Customers accept additional invest
O n
e
r
Proof of concept
n
r
Quality assurance
a
e
l
n
U
r
s
a
e
P
S A P
S A P
P a
Java knowhow required
s e
r
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
Agenda
What MFS Is Good For & How It Works
I
l y
n
t
O n
e
r
n
r
a
e
l
1. Which business needs are addressed by MFS?
n
t
U
r
s
2. EWM and MFS - How are they integrated?
a
e
P
S A P
3. What are the basic concepts of MFS?
S A P
P a
s e
r
U
t
n
6. How can it be tested?
l
e
a
r
n
O
e
n
t
l
n
y
I
I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
Interaction/Influencing Factors/Pressure
I
l y
n
t
O n
e
r
Undocumented legacy
n
r
system
a
e
l
n
t
U
Retrofit for vendor internal Inexperienced staff / not
r
s
MFS-PLC interface cooperating PLC vendor
a
e
P
S A P
S A P
P a
7*24h
s e
r
U
t
n
l
e
a
r
n
Non standard
r
High Volume
O
communication protocol
e
n
t
l
n
y
I
I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
I
l y
n
t
O n
e
r
n
r
a
e
l
n
t
U
r
s
a
e
P
S A P
S A P
P a
s e
r
U
t
n
Material Flow System
l
e
a
r
n
r
O
e
n
t
l
n
y
I
I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
I
l y
n
t
O n
e
r
n
SAPSPM 2 days EWM100 3 days EWM110 5 days EWM120 5 days
r
a
e
l
Management Management Management Extended Warehouse
n
U
r
s
a
e
EWM210 3h
P
S A P
(MFS) in EWM
S A P
EWM220 2h
P a
RadioFrequency
s e
Framework (RF)
in EWM
r
U
t
Clasroom training
n
EWM230 2h
l
e
Recorded clasroom training
a
ITSMobile
r
& RadioFrequency
n
in EWM
r
O
e
n
t
l
n
y
I
I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
Agenda
Setup PLC Communication
I
l y
n
t
O n
e
r
n
r
a
e
l
n
t
U
2. Maintain PLC master data
r
s
a
e
P
S A P
4. Setup SAP PCo
S A P
P a
s e
r
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
MFS Objects
I
l y
n
t
O n
EWM
e
WO
r
n
r
a
e
WT Queue Rsrc
l
HU
n
t
U
r
s
a
e
P
S A P
CP CP CP
S A P
Segm
Channel
P a
s e
r
U
t
n
l
e
a
r
PLC
n
r
O
e
n
t
l
n
y
I
CP CP
CP RSRC
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
I
Telegram Type Telegram Category
l y
n
(customizable)
t
O n
e
SYES Synchonization Setup EWM to initiate connection to PLC
r
n
r
a
SYBE Synchronization Start PLC to start synchronization mode (answer to SYES)
e
l
n
SYEN Synchronization End PLC to indicate that its send buffer is empty and to
t
U
close synchronization mode
r
s
a
e
LIFE Life Telegram EWM and PLC to check the connection
P
S A P
S A P
STAR Status Request EWM to aks for the current availability of an equipment
P a
available resp. available again
s e
r
U
t
n
WTCO Warehouse Task Confirmation PLC to indicate that a task has been executed
l
e
a
r
n
O
e
n
t
l
n
y
I
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
Communication Protocol
Synchronisation after Restart
I
l y
n
EWM (Client) Channel PLC (Server)
t
O n
e
r
n
Sync Request
r
a
The PLC acts as server
e
l
n
U
EWM initates the communication process
r
s
by sending a synchronization request Sync Begin
a
e
P
S A P
S A P
P a
s e
r
U
t
from the PLC before it starts to send
n
new tasks
l
e
a
Sync End
r
n
r
O
e
n
t
l
Next Task
n
y
I
Communication Protocol
Message Buffering
I
l y
n
EWM EWM
t
O n
Application Channel
e
PLC
r
n
r
a
e
l
n
Tele 1
t
U
r
s
a
e
P
Tele 2 Tele 1
S A P
S A P
Buffer
P a
s e
Buffer
r
U
t
Ack 1
n
Table /SCWM/MFSDELAY
l
e
a
r
n
r
O
e
n
t
l
n
y
Tele 2
I
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
Communication Protocol
Send and Receive at the Same Time
I
l y
n
EWM PLC
t
Channel Channel
O n
e
r
n
r
a
e
l
Tele 1
n
Tele 1
t
U
r
s
a
e
P
S A P
S A P
P a
while waiting for an
s e
r
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
Communiaction Protocol
Life Check & Channel Reconnect
I
EWM PLC
l y
n
t
O n
e
Tele 1
r
n
r
a
e
l
Tele 2
n
U
• Checks for outstanding ack. telegrams
r
s
Tele 2
a
e
?
P
sequence number
S A P
• Then closes and reopens the channel
S A P
Tele 2
• Repeats the same telegram again (same
sequence number)
Close Event
P a
• Sends LIFE check telegrams on timeout
s e
r
number
U
Tele 2 (!)
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
I
l y
n
1. Telegram structures
t
O n
e
2. Interface Types
r
n
r
a
3. PLCs and communication channels
e
l
n
t
U
4. PLC and EWM exceptions
r
s
a
e
P
S A P
S A P
P a
s e
r
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
Telegram Structure
Header and Body
I
All telegram structures must include a header structure (as .INCLUDE)
l y
n
Used for the communication protocol
t
O n
e
Identical for all telegrams of a single PLC
r
n
r
a
e
l
Header Structure must include the fields Any fixed sequence of these fields within the header
n
structure is allowed.
t
– Sequence number
U
r
s
If one of these fields is missing in a given protocol
a
e
– Handshake flag BAdIs have to be implemented (manipulation of
P
S A P
S A P
– Communication error
To be set by the receiver in the acknowledgement telegram. Should be blank or zero.
– Telegram type
P a
Defines the scope of the telegram and the structure of the rest of the telegram
s e
r
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
I
l y
n
EWM
t
O n
e
Structure /SCWM/S_MFS_TELETOTAL
r
n
SEQU_NO
r
a
TELETYPE
e
l
HUIDENT
n
HUTYP
...
t
U
RSRC
r
s
CP
a
/SCWM/S_MFS_TELETOTAL CS
e
Function
P
WT
Modul X
S A P
Z_TELE: ...
S A P
SOURCE SEQU_NO
Field Mapping by Field Name DEST TELETYPE
... HUIDENT Z_TELE
LENGTH SOURCE
WIDTH
P a
DEST
s e
... MFS_ERROR
MFS_ERROR
r
U
t
n
l
e
a
r
String max 255 Byte
n
alphanumeric characters
r
O
only!
e
n
t
l
n
y
PLC SEQU_NO
Z_TELE
I
TELETYPE
HUIDENT
PLC Event SOURCE
DEST
MFS_ERROR
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
I
l y
n
1. Telegram structures
t
O n
e
2. Interface Types
r
n
r
a
3. PLCs and communication channels
e
l
n
t
U
4. PLC and EWM exceptions
r
s
a
e
P
S A P
S A P
P a
s e
r
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
I
l y
n
t
O n
e
r
Interface Type PLC
n
r
a
5.1 and higher
e
l
n
t
U
Telegram
r
PLC
s
Structures
a
e
P
5.0
S A P
S A P
P a
s e
r
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
I
Interface Types combine a set of properties and are assigned to PLCs
l y
n
t
O n
e
r
n
r
a
Telegram Structures Telegram Structures
e
l
n
t
U
Telegram Types Telegram Types
r
s
a
e
Error Codes Error Codes
P
S A P
S A P
P a
s e
r
U
t
n
l
e
a
r
n
r
O
e
PLC
n
CONSYS1 CRANE01 CRANE02 CRANE03
t
l
n
y
I
CP CP
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
Telegram Types
I
PLC
l y
n
t
O n
e
r
n
r
a
e
l
n
t
U
r
s
a
e
P
S A P
S A P
P a
identifiers for telegram categories.
s e
r
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
I
l y
n
1. Telegram structures
t
O n
e
2. Interface Types
r
n
r
a
3. PLCs and communication channels
e
l
n
t
U
4. PLC and EWM exceptions
r
s
a
e
P
S A P
S A P
P a
s e
r
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
I
PLC
l y
n
communication protocol and to indicate
t
O n
e
receiver.
r
n
r
a
e
l
n
t
U
r
s
a
e
P
S A P
S A P
P a
s e
r
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
PLC Customizing
I
l y
n
t
connected using the MFS telegram interface,
O n
e
Recommendations
r
must be defined as a PLC.
n
r
a
Put away – WPT:
e
l
Rel. 5.0 only
n
U
r
s
a
e
Is used to post an HU to a new location in case of flow
P
error.
S A P
Use a WPT allowing “confirm immediately”.
S A P
P a
s e
r
will post the HU to the new location and make this
U
t
exception visible to the supervisor
n
l
Mapping:
e
a
r
n
O
use if the PLC cannot deal with EWM bin names.
e
n
t
Identification:
l
n
y
Is set as sender in outgoing telegrams and expected in
I
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
I
To every PLC at least one communication channel must be defined
l y
n
t
O n
e
Recommendations Communication Channel
r
n
r
a
e
l
n
U
otherwise BAdI must be implemented
r
s
a
e
P
S A P
S A P
P a
no exceptional coding needed
s e
r
U
t
n
Use fixed telegram length
l
e
eases programming on PLC side
a
r
n
Use an exception code which is configured to close and reopen the channel in
r
O
case of connection loss (int. process code “REST”)
e
n
otherwise connection won’t be reestablished
t
l
n
Use synchronization
y
will force MFS to immediately send a telegram if a channel is started
I
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
I
l y
n
1. Telegram structures
t
O n
e
2. Interface Types
r
n
r
a
3. PLCs and communication channels
e
l
n
t
U
4. PLC and EWM exceptions
r
s
a
e
P
S A P
S A P
P a
s e
r
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
I
l y
n
t
O n
e
r
n
r
a
e
l
n
t
U
r
s
a
e
P
S A P
From PLC
S A P
To PLC
P a
s e
r
What code is to be set in a telegram to the PLC in case of Error ...?
U
t
n
l
e
Match PLC Errors to EWM Exceptions:
a
r
n
r
O
e
n
t
l
n
y
I
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
Agenda
Setup PLC Communication
I
l y
n
t
O n
e
r
n
r
a
e
l
n
t
U
2. Maintain PLC master data
r
s
a
e
P
S A P
4. Setup SAP PCo
S A P
P a
s e
r
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
I
l y
n
1. Create RFC destination
t
O n
e
2. Maintain PLC: Assign RFC destination
r
n
r
a
3. Maintain communication channel: Assign IP address and port
e
l
n
t
U
r
s
a
e
P
S A P
S A P
P a
s e
r
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
I
l y
n
IMG Master Data
t
O n
e
r
n
r
a
e
l
n
U
Except. Deviation RFC Destination
r
s
a
Tele Logging
e
Activate Mapping
P
S A P
S A P
P a
s e
r
U
t
n
l
e
a
r
Timeouts
n
r
O
Telegr. Length
e
n
Handshake
t
l
n
y
Except. Restart
I
Synchronisation
Std. ErrorCode
...
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
I
l y
n
EWM
t
O n
e
r
n
r
a
e
l
n
t
U
r
s
a
e
P
S A P
S A P
SM59
P a
RFC Destination ZTR_PLC_GATEWAY2
s e
Program ID TR_PLC_GATEWAY2
r
U
t
n
l
e
a
r
n
RFC-Adapter
r
O
e
n
t
l
n
y
I
PLC
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
Maintain PLC
Assign Communication Layer and RFC Destination
I
l y
n
EWM
t
O n
e
r
n
r
a
e
l
n
t
U
r
s
a
e
P
S A P
S A P
SM59
P a
RFC Destination ZTR_PLC_GATEWAY2
s e
Program ID TR_PLC_GATEWAY2
r
U
t
n
l
e
a
r
n
RFC-Adapter
r
O
e
n
t
l
n
y
I
PLC
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
I
l y
n
EWM
t
O n
e
r
n
r
a
e
l
n
t
U
r
s
a
e
P
S A P
S A P
SM59
P a
RFC Destination ZTR_PLC_GATEWAY2
s e
Program ID TR_PLC_GATEWAY2
r
U
t
n
l
e
a
r
n
RFC-Adapter
r
O
e
n
t
l
n
y
I
Socket Server
PLC
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
I
l y
n
EWM
t
O n
e
r
n
r
a
e
l
n
t
U
r
FM /SCWM/MFS_RECEIVE2
s
a
e
P
S A P
S A P
SM59
P a
RFC Destination ZTR_PLC_GATEWAY2
s e
Program ID TR_PLC_GATEWAY2
r
U
t
n
l
e
a
r
RFC Handler
n
O
SAP and calls /SCWM/MFS_RECEIVE2 Program ID
e
n
Socket Client
t
l
n
y
I
Socket Server
PLC
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
Runtime
I
l y
n
EWM I love you, it
t
CONSYS1
works..!
O n
e
r
Me too
n
r
a
e
l
n
t
U
r
/SCWM/MFS_RECEIVE2
s
a
e
P
S A P
S A P
SM59
P a
RFC Destination ZTR_PLC_GATEWAY2
s e
Program ID TR_PLC_GATEWAY2
r
U
t
n
l
e
a
r
RFC Handler
n
RFC-Adapter
r
O
e
Socket Client
n
t
l
n
y
I
... words
Socket Server
..
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
Agenda
Setup PLC Communication
I
l y
n
t
O n
e
r
n
r
a
e
l
n
t
U
2. Maintain PLC Master Data
r
s
a
e
P
S A P
4. Setup SAP PCo
S A P
P a
s e
r
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
I
l y
n
I love you,
EWM CONSYS1 it
t
works..!
O n
e
r
Me too
n
r
a
e
l
n
t
U
r
FM /SCWM/MFS_RECEIVE2
s
... confirming
a
everything
e
P
S A P
S A P
FM /SCWM/MFS_SIM_RECEIVE
Me too
P a
s e
RFC Destination
r
U
t
n
l
e
a
r
RFC Handler
n
RFC-Adapter
r
O
e
n
Socket Client
t
l
n
y
I
Socket Server
PLC
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
I
l y
n
The internal function module /SCWM/MFS_SIM_RECEIVE includes:
t
O n
e
Telegram Acknowledgement
r
n
r
Synchronization
a
e
l
n
Status Request
t
U
r
s
a
e
P
S A P
Customizing is used
S A P
P a
□ Scanner Messages
s e
r
□ Location left telegram
U
t
n
□ Forced Errors (equipment fault, outline error, bin occupied, ...)
l
e
a
r
n
r
O
e
n
t
l
n
y
I
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
Agenda
Setup PLC Communication
I
l y
n
t
O n
e
r
n
r
a
e
l
n
t
U
2. Maintain PLC Master Data
r
s
a
e
P
S A P
4. Setup SAP PCo
S A P
P a
s e
r
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
PCo in General
I
l y
n
Is free of charge if the customer has licensed EWM
t
O n
e
r
Can be downloaded from service market place (software distribution center)
n
r
a
e
l
PCo 2.1 currently in ramp-up (planned end: June 2010)
n
t
U
r
s
a
e
P
http://www.sap.com/solutions/manufacturing/index.epx
S A P
S A P
P a
s e
r
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
Installing PCo
I
PCo provides different shop floor communication techniques.
l y
n
For EWM we need Socket Agent and RFC Destination only.
t
O n
e
r
n
r
a
e
l
n
t
U
r
s
a
e
P
S A P
S A P
P a
s e
r
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
I
l y
n
EWM SYES
t
LIFE
O n
e
SYBE
r
SYEN
n
LIFE
r
a
e
l
n
t
U
r
FM /SCWM/MFS_RECEIVE2
s
a
e
P
S A P
S A P
SM59
P a
RFC Destination ZTR_PLC_GATEWAY2
s e
Program ID TR_PLC_GATEWAY2
r
U
t
n
l
e
a
„Destination Channel“
r
„Notification“
n
„Agent
r
O
Instance“
e
„Source Channel“
n
t
l
n
y
I
Socket Server
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
I
l y
PCo
n
t
O n
e
PLC Socket Service RFC
SAP
r
n
r
a
e
l
n
t
U
r
s
a
e
P
S A P
S A P
Create
source
uncheck
P a
system
s e
r
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
I
l y
PCo
n
t
O n
e
PLC Socket Service RFC
SAP
r
n
r
a
e
l
n
t
U
Activate
r
s
reliability
a
e
Create
P
S A P
destination
S A P
system Program ID
maintained in
sm59
P a
s e
r
SAP App. server
U
t
& gateway
n
l
e
service
a
r
n
r
O
e
n
t
SAP credentials
l
n
y
I
Test connection
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
I
l y
n
PCo
t
O n
e
PLC SAP
r
Socket Service RFC
n
r
a
e
l
n
t
U
r
s
a
e
P
S A P
S A P
Create agent
P a
instance
s e
(Windows
r
U
service)
t
n
l
e
a
r
n
r
O
Option: Start
e
n
automatically
t
l
n
y
I
uncheck
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
I
l y
n
PCo
t
O n
e
PLC SAP
r
Socket Service RFC
n
r
a
e
l
n
t
U
r
s
a
e
P
S A P
S A P
Enable
notification
trigger
P a
s e
Add
r
U
t
notification
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
I
l y
n
PCo
t
O n
e
PLC SAP
r
Socket Service RFC
n
r
a
e
l
n
t
U
r
s
a
e
P
S A P
S A P
Add notification
destination
(RFC)
P a
s e
r
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
Agenda
Setup PLC Communication
I
l y
n
t
O n
e
r
n
r
a
e
l
n
t
U
2. Maintain PLC Master Data
r
s
a
e
P
S A P
4. Setup SAP PCo
S A P
P a
s e
r
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
I
l y
n
Is installed locally on a PC
t
O n
e
r
Requires Java runtime environment 6 (jre6)
n
r
a
e
l
Needs to be configured according to the MFS project in local .csv files
n
t
U
Communication channels
r
s
a
e
Telegram types
P
S A P
Telegram structure header
S A P
P a
s e
r
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
Emulation reads its settings from
I
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
I
Maintain socket ports Maintain telegram type IDs
l y
n
t
O n
e
r
n
r
a
e
l
n
t
U
r
s
a
e
P
S A P
S A P
P a
s e
r
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
I
Double click “start.bat”
l y
n
t
O n
e
r
n
r
a
e
l
n
t
U
r
s
a
e
P
S A P
S A P
P a
s e
r
U
t
n
l
e
Activate telegram logging to console:
a
r
n
r
O
e
n
t
l
n
y
I
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
I
l y
n
Activate logging monitors
t
Start Emulation (response times, number of
O n
e
telegrams/s)
r
n
r
a
e
l
n
t
U
r
s
a
e
P
S A P
S A P
P a
s e
r
U
t
n
l
e
a
r
n
r
O
e
n
Set an HU to ID point
t
l
conveyor (right click)
n
y
I
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
I
l y
n
t
O n
e
r
n
r
a
e
l
n
t
U
r
s
a
e
P
S A P
S A P
P a
s e
r
U
t
n
Material Flow System
l
e
a
r
n
r
O
e
n
t
l
n
y
I
I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
I
l y
n
t
O n
e
r
n
SAPSPM 2 days EWM100 3 days EWM110 5 days EWM120 5 days
r
a
e
l
Management Management Management Extended Warehouse
n
U
r
s
a
e
EWM210 3h
P
S A P
(MFS) in EWM
S A P
EWM220 2h
P a
RadioFrequency
s e
Framework (RF)
in EWM
r
U
t
Clasroom training
n
EWM230 2h
l
e
Recorded clasroom training
a
ITSMobile
r
& RadioFrequency
n
in EWM
r
O
e
n
t
l
n
y
I
I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
Agenda
Setup Material Flow
I
l y
n
t
O n
e
r
n
r
a
e
1. Warehouse Layout
l
n
t
U
2. Routing
r
s
a
3. Task Creation
e
P
S A P
4. Task Communication
S A P
P a
6. Capacity Management
s e
r
7. Exceptions
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
Warehouse Layout
Storage Types and Roles
I
l y
n
storage locations and assign appropriate role.
t
O n
e
CR3
r
n
CR1
TRR01
r
a
Final storage locations (aisles): CR2
e
l
• Storage type role „J“: Automatic Warehouse
n
t
U
r
s
a
e
P
S A P
S A P
P a
s e
r
U
CP01 CP10
t
CP02 CP03 CP05 CP07
(IP) (IP)
n
l
e
a
r
CP08
n
O
e
CP09
n
t
l
n
y
I
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
Warehouse Layout
Storage Bins – Communication Points - Resources
I
l y
n
Resource
t
• MFS controls HUs
O n
e
CR3
r
• HUs can be posted to storage bins or
n
CR1
TRR01
resources
r
a
CR2
Every MFS relevant conveyor
e
l
n
U
storage bin and Communication
r
s
a
Point
e
P
• Communication Points are linked to CP12 CP13 CP16 CP17 CP20 CP21
S A P
S A P
P a
• Physical State Point and
s e
TCAR
Storage Bin
r
• Telegram Processing
U
CP01 CP10
t
CP02 CP03 CP05 CP07
(IP) (IP)
n
• other MFS relevant settings
l
e
a
r
CP08
n
O
e
CP09
n
t
l
n
y
Storage Bin
I
Clearing
Resource
(optional)
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
Warehouse Layout
Communication Points
I
l y
n
t
O n
e
r
n
HU exception will
r
be cleared
a
Allows to control
e
l
the function
n
module to deal
t
U
with a PLC Use for ID point
r
s
telegram from this only
a
e
CP
P
S A P
Indicates ID Point
S A P
resp. conveyor
end point (normal Stop layout-
or NIO) oriented storage
control
P a
Switch off CP
s e
r
slide) What to do in
U
t
case of
n
bottleneck
Number of HUs
l
e
(STAY, NSND)
a
allowed at CP
r
n
and mode to
calculate them Next CP
r
O
direction NIO
e
n
t
l
n
y
Deactivate
I
capacity /
availability check
direction NIO
RF WT to clearing area at the end of
NIO conveyor
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
Warehouse Layout
Communication Points
I
l y
n
t
Event: Scanner message for HU 2
O n
e
r
n
forbidden
r
a
e
l
CP without scanner flag (CP FIFO): 3 2 1
n
U
WT for HU 1 has been sent
r
s
CP01
a
e
No scanner flag
P
S A P
S A P
P a
s e
r
allowed
U
t
CP with scanner flag activated (no CP FIFO):
n
3 2 1
l
e
a
r
n
CP01
r
O
Scanner flag
e
n
t
l
n
y
I
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
Warehouse Layout
Communication Points
I
l y
n
t
O n
e
r
n
r
a
Customizing Application
e
l
n
t
U
r
s
a
e
CP CP Storage Bin
P
S A P
S A P
Assign
• storage bin
P a
s e
r
U
t
n
l
e
a
r
n
r
O
generated Manual Assignment
e
n
t
l
n
y
I
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
Warehouse Layout
Resources
I
l y
n
t
Customizing
O n
Application
e
r
n
r
a
Use type
e
l
Resource Type Resource
n
t
U
r
s
a
e
P
Create manually
S A P
S A P
P a
s e
r
U
t
n
l
e
a
r
Above all try to always Capacity:
n
O
after a retrieval task and that are optimized
e
n
vice versa by the PLC itself
t
l
n
y
I
Warehouse Layout
Conveyor Segments
I
l y
n
t
• Segments represent conveyors between CPs
O n
e
CR3
r
• Segments are assigned to intermediate destinations
n
CR1
TRR01
in the layout-oriented storage control (customizing)
r
a
CR2
e
l
n
U
capacity and equipment fault during task execution
r
s
a
e
• Segment can be blocked by
P
S A P
• PLC state telegram
S A P
• Warehouse Monitor
CP11 CP14 CP15 CP18 CP19 CP22
P a
Segment Group
s e
TCAR
r
U
CP01 CP10
t
CP02 CP03 CP05 CP07
• Segment groups combine a number of segments. (IP) (IP)
n
Advantage: A complete area can be set out of order
l
e
a
r
CP08
n
O
e
CP09
n
t
l
• Recommendation:
n
y
I
Segment capacity calculation: Number of WTs sent to the PLC and not yet confirmed
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
Agenda
Setup Material Flow
I
l y
n
t
O n
e
r
n
r
a
e
1. Warehouse Layout
l
n
t
U
2. Routing
r
s
a
3. Task Creation
e
P
S A P
4. Task Communication
S A P
P a
6. Capacity Management
s e
r
7. Exceptions
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
Routing
Storage Control Groups
I
l y
n
Storage control groups RACK 1
t
O n
e
r
• Are property of storage bins.
n
r
BIN
a
e
l
BIN
n
BIN
t
U
r
s
a
e
P
S A P
Storage Control Group
S A P
RCK1
BIN
BIN CP01 CP02
P a
s e
BIN
r
BIN RACK 2
U
t
Storage Control Group Storage Control Group
n
CP01 CP02
l
e
a
BIN
r
n
BIN
r
O
That means: 3 names for the same physical
e
BIN
n
conveyor location!
t
l
n
y
I
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
Routing
Standard Routing for Slow* Moving HU Types
I
l y
n
t
O n
e
WT1
HU
inactive
r
Step 1
n
r
a
WT2
e
active
l
n
t
U
r
s
a
e
P
S A P
WT1
HU
S A P
inactive
Step n
WT3
P a
active
s e
r
Bin 1 Bin 2 Bin n Final Bin
U
t
n
l
e
a
WT1
r
HU
active
n
Final Step
r
O
e
n
t
l
n
y
I
Routing
Fast* Routing Option (NL Development)
I
Product WT
l y
n
Product Requirement inactive active
t
HU Final Bin
O n
e
Activity Area1
r
n
r
At Scanner:
a
e
l
Scanner 2
n
U
3. Evaluate sort report HU WT CONV1 (confirmed) HU WT WA_AA1 (confirmed)
r
HU WT LOOP1 (confirmed)
s
(post sort result)
a
e
P
S A P
HU posted to storage GR Bin Bin Work Station
S A P
P a
s e
r
Decision Logistical PLC Data After
• Based on logistical destinations
U
t
Point Destination Destination Sorting
n
• Logistical destinations determined by CP specific
l
e
Z-MFS action FM triggered by PLC telegrams,
a
r
considering Scanner1 ELSE LEFT CONV1
n
r
O
• final destination (inactive WT) Scanner2 Activity Area 1 CHUTE1 LOOP1
e
n
• HU exceptions (weight, differences, user
t
l
exception, …)
n
y
Scanner2 ELSE CHUTE3
I
• HU posting
Scanner3 Activity Area 1 LEFT WS_AA1
• after sorting
• May be not necessary for every step Scanner3 ELSE STRAIGHT
Routing
Standard Routing in Case of Exceptions
I
l y
n
t
O n
e
r
HU marked with exception code
n
r
a
e
l
n
t
U
MHUX
r
s
a
e
P
S A P
CP01 NIO: CP03 NIO: CP04 CP03
S A P
P a
s e
r
U
t
n
l
e
a
r
n
NIO CP04
r
O
e
n
t
l
n
y
I
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
Routing
Identification Point
I
Layout Oriented Storage Control with ID Point
l y
n
t
O n
e
9010
r
CR3
0280
n
CR1
r
TRR01
a
CR2
e
HU 1
l
n
t
U
r
s
a
e
P
S A P
CP11 CP14 CP15 CP18 CP19 CP22
S A P
TCAR
P a
s e
r
CP09
U
t
n
l
e
Destination of put away task is changed to the storage bin specified in layout
a
r
oriented storage control
n
r
O
e
n
t
l
n
y
I
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
Routing
Pick Point – Goods to Man
I
l y
CR3
n
Full pallet stock removal: No pick point CR1
t
TRR01
O n
CR2
e
r
n
r
a
e
l
n
t
U
CP11 CP14 CP15 CP18 CP19 CP22
r
s
a
TCAR
e
P
CP01 CP10
CP02 CP03 CP05 CP07
(IP) (IP)
S A P
S A P
CP09
P a
s e
r
U
t
n
l
e
a
r
n
O
e
n
t
l
n
y
Pick Point activated
I
Pick Point
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
Routing
Pick Point – Goods to Man
I
l y
n
CR1
t
Pos 10: 1000 kg Prod A 65 TRR01
O n
CR2
e
Pos 20: 2 Pc Prod B
r
66
n
r
a
e
l
n
U
CP11 CP14 CP15 CP18 CP19 CP22
HU 66: 371 Pc Prod B pick point
r
s
a
TCAR
e
P
CP01 CP10
CP02 CP03 CP05 CP07
(IP) (IP)
S A P
EWM creates 2 WTs for a stock removal requirement
S A P
CP09
HU-WT.
P a
If the HU-WT can not be executed directly a 2nd HU-WT is created.
s e
1000 kg
r
2 Pc
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
9020 GI-Zone
y
Legend
I
Inactive Active
Product WT
HU WT
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
Routing
Pick Point – Goods to Man
I
l y
CR3
n
CR1
t
TRR01
O n
CR2
e
The source location of all WTs is adjusted step by step
r
n
r
a
e
CP12
65
CP13 CP16 CP17 CP20
66
CP21
l
n
t
U
CP11 CP14 CP15 CP18 CP19 CP22
r
s
a
TCAR
e
P
CP01 CP10
CP02 CP03 CP05 CP07
(IP) (IP)
S A P
S A P
CP09
P a
s e
r
1000 kg
U
t
2 Pc
n
l
e
a
r
n
r
O
e
n
t
l
n
9020 GI-Zone
y
Legend
I
Inactive Active
Product WT
HU WT
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
Routing
Pick Point – Goods to Man
I
l y
CR3
n
CR1
t
TRR01
O n
CR2
e
The source location of all WTs is adjusted step by step
r
n
r
a
e
l
n
t
U
CP11
65
CP14 CP15 CP18 CP19
66
CP22
r
s
a
TCAR
e
P
CP01 CP10
CP02 CP03 CP05 CP07
(IP) (IP)
S A P
S A P
CP09
P a
s e
r
1000 kg
U
t
2 Pc
n
l
e
a
r
n
r
O
e
n
t
l
n
9020 GI-Zone
y
Legend
I
Inactive Active
Product WT
HU WT
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
Routing
Pick Point – Goods to Man
I
l y
CR3
n
CR1
t
TRR01
O n
CR2
e
The source location of all WTs is adjusted step by step
r
n
r
a
e
l
n
t
U
CP11 CP14 CP15 CP18 CP19 CP22
r
s
a
TCAR
e
P
CP02
CP01
(IP)
CP03
65 66
CP05 CP07
CP10
(IP)
S A P
S A P
CP09
P a
s e
r
1000 kg
U
t
2 Pc
n
l
e
a
r
n
r
O
e
n
t
l
n
9020 GI-Zone
y
Legend
I
Inactive Active
Product WT
HU WT
Routing
Pick Point – Goods to Man
I
l y
CR3
n
CR1
t
TRR01
O n
CR2
e
r
n
r
a
The inactive WT gets active if there is no further
e
l
n
intermediate destination
t
U
CP11 CP14 CP15 CP18 CP19 CP22
r
s
a
TCAR
e
P
CP01 CP10
CP02 CP03 CP05 CP07
(IP) (IP)
S A P
S A P
CP08
CP00 CP04
65
CP06
66
(PP)
CP09
P a
s e
1000 kg
r
U
t
n
l
2 Pc
e
a
r
n
r
O
e
n
t
l
n
9020 GI-Zone
y
Legend
I
Inactive Active
Product WT
HU WT
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
Routing
Pick Point – Goods to Man
I
Work Center KPL1
l y
CR3
n
CR1
t
TRR01
O n
CR2
e
r
A)
n
r
a
e
l
n
t
U
B) CP11 CP14 CP15 CP18 CP19 CP22
r
s
a
e
P
CP01 CP10
confirms WT 78286 CP02
(IP)
CP03 CP05 CP07
(IP)
S A P
S A P
101 CP09
P a
s e
r
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
Routing
Pick Point – Goods to Man
I
Work Center KPL1
l y
CR3
n
CR1
t
TRR01
O n
C) CR2
e
Close customer HU 101:
r
n
Two new WTs for moving it to the GI-Zone are created.
r
a
e
l
n
t
U
CP11 CP14 CP15 CP18 CP19 CP22
r
s
a
TCAR
e
P
CP01 CP10
CP02 CP03 CP05 CP07
(IP) (IP)
S A P
S A P
101 CP09
P a
s e
r
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
9020 GI-Zone
y
Legend
I
Inactive Active
Product WT
HU WT
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
Routing
Pick Point – Goods to Man
I
l y
CR3
n
CR1
t
TRR01
O n
CR2
e
In this example the customer HU is moved to the GI-
r
Zone by use of layout-oriented storage control.
n
r
a
e
l
n
t
U
CP11 CP14 CP15 CP18 CP19 CP22
r
s
a
TCAR
e
P
CP02
CP01
(IP)
CP03 CP05 CP07
101
CP10
(IP)
S A P
S A P
CP09
P a
s e
r
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
9020 GI-Zone
y
Legend
I
Inactive Active
Product WT
HU WT
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
Routing
Pick Point – Goods to Man
I
Work Center KPL1
l y
CR3
n
CR1
t
TRR01
O n
e
r
n
r
a
e
l
n
t
U
CP11 CP14 CP15 CP18 CP19 CP22
r
s
a
TCAR
e
P
CP01
CP02
(IP)
CP03
101
CP05 CP07
CP10
(IP)
S A P
S A P
CP09
P a
s e
r
U
t
n
l
e
WT destination is changed to CP10 (ID point for CP08) based on customizing:
a
r
n
r
O
e
n
t
l
n
y
Legend
9020 GI-Zone
I
Inactive Active
Product WT 65
HU WT
Routing
Pick Point – Goods to Man
I
l y
CR3
n
CR1
t
TRR01
O n
CR2
In this example the storage HU is moved back to the
e
r
high bay storage by use of a second ID point at CP10
n
and the layout-oriented storage control.
r
a
e
l
n
t
U
CP11 CP14 CP15 CP18 CP19 CP22
r
s
a
TCAR
e
P
CP01 CP10
CP02
(IP)
CP03 CP05 CP07
66
(IP)
S A P
S A P
CP09
P a
s e
r
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
9020 GI-Zone
y
Legend
I
Inactive Active
65
Product WT
HU WT
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
Agenda
Setup Material Flow
I
l y
n
t
O n
e
r
n
r
a
e
1. Warehouse Layout
l
n
t
U
2. Routing
r
s
a
3. Task Creation
e
P
S A P
4. Task Communication
S A P
P a
6. Capacity Management
s e
r
7. Exceptions
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
Task Creation
Warehouse Tasks and Warehouse Orders
I
l y
n
t
Manual Execution (RF) Execution by a PLC
O n
e
r
n
r
a
Warehouse Task 1 Warehouse Task 2 Warehouse Task 1 Warehouse Task 2
e
l
n
t
U
1:1
r
s
n:1
a
e
Warehouse Order 1 Warehouse Order 2
P
Warehouse Order 1
S A P
S A P
Queue 1 Queue 1
P a
s e
1:1
n:m
r
U
t
n
l
Resource 1 Resource 2
e
Resource
a
r
n
n:1
r
O
e
n
PLC
t
l
n
y
I
Task Creation
WO Creation and Queue Determination
I
l y
n
t
O n
e
r
CP CP
n
r
a
e
l
n
t
U
r
s
a
e
P
S A P
S A P
Warehouse Task
P a
s e
r
U
t
n
l
e
Queue Warehouse Order
a
r
n
r
O
e
is communicated to executes
n
t
l
n
y
PLC optional: Resource
I
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
Task Creation
WO Creation
I
l y
n
t
From Storage Bin To Storage Bin
O n
e
r
n
r
a
e
l
n
t
U
Warehouse Task Warehouse Process Type Activity MFSI
r
s
a
To Activity
e
Area
P
From Activity
Area
S A P
S A P
P a
s e
r
U
t
combines tasks
n
Queue Warehouse Order
l
MFS 1:1
e
a
r
n
r
O
is communicated to executes
e
n
t
l
PLC Resource
n
y
I
Legend
for technical reason only
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
Task Creation
WO Creation
I
l y
n
t
O n
e
Define a limit with 1 item / WO WO Creation Rule for PLCs
r
n
r
a
e
l
n
t
U
r
s
a
e
P
S A P
S A P
P a
s e
r
Apply PLC WOCR based on activity area and activity
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
Task Creation
Queue Determination
I
l y
n
Source Storage Bin Destination Storage Bin
t
O n
e
r
n
Warehouse Task
r
a
e
l
n
t
U
r
s
a
Warehouse Process
e
Bin Access Type Activity MFSI
Type
P
S A P
S A P
P a
from to
s e
r
Activity Area Queue Determination Criteria Activity Area
U
t
n
l
e
a
r
n
combines tasks
Queue Warehouese Order
r
O
MFS 1:1
e
n
t
l
n
is communicated to
y
executes
I
PLC Resource
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
Task Creation
Queue Determination
I
l y
n
Define bin access types per PLC
t
O n
e
r
n
r
a
e
l
Carefully consider queue access sequence
n
t
U
r
s
a
e
P
S A P
S A P
P a
s e
r
U
t
n
l
e
a
r
n
r
O
Assign operation environment to queue
e
n
t
l
n
y
I
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
Agenda
Setup Material Flow
I
l y
n
t
O n
e
r
n
r
a
e
1. Warehouse Layout
l
n
t
U
2. Routing
r
s
a
3. Task Creation
e
P
S A P
4. Task Communication
S A P
P a
6. Capacity Management
s e
r
7. Exceptions
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
Task Communication
Material Flow Related Telegram Categories
Usage
I
l y
n
t
O n
e
SYES Synchonization Setup EWM to initiate connection to PLC
r
n
r
a
e
l
n
SYEN Synchronization End PLC to indicate that its send buffer is empty and to
t
U
close synchronization mode
r
s
a
e
LIFE Life Telegram EWM and PLC to check the connection
P
S A P
STAR Status Request EWM to aks for the current availability of an equipment
S A P
P a
available resp. available again
s e
r
U
t
n
WTCO Warehouse Task Confirmation PLC to indicate that a task has been executed
l
e
a
r
LOCL Location Left PLC to indicate that a HU has left a location
n
r
O
e
n
WTCR Cancellation Request EWM to cancel a warehouse task
t
l
n
y
I
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
Task Communication
Telegram Types
I
PLC
l y
n
t
O n
e
r
n
r
a
e
l
n
t
U
r
s
a
e
P
S A P
S A P
P a
s e
r
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
Task Communication
Telegram Flow Conveyors
I
EWM PLC
l y
n
t
O n
e
r
Warehouse task
n
r
a
• Scanner (optional)
e
l
n
• WT
t
U
r
s
a
e
P
• WT confirmation
S A P
S A P
Task cancellation
P a
• Cancel request
s e
• Cancel response
r
U
t
n
l
e
Equipment state
a
r
n
O
e
n
• State
t
l
n
y
I
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
Task Communication
Telegram Flow Resources
I
EWM PLC
l y
n
t
O n
e
r
Warehouse task
n
r
a
• WT
e
Control of WT Confirmation:
l
n
U
r
• Destination (optional)
s
a
e
P
• WT confirmation
S A P
S A P
Task cancellation
P a
• Cancel request
… same as conveyors
s e
• Cancel response
r
U
t
n
l
e
Equipment state
a
r
n
O
e
n
• State
t
l
n
y
I
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
Task Communication
Bin Address Mapping for Telegram Communication
I
l y
n
t
O n
e
r
Application Data: Map EWM storage bin
n
names to PLC bin names
r
a
e
l
n
t
U
r
s
IMG: Activate Mapping on PLC level
a
e
P
S A P
S A P
P a
s e
r
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
Agenda
Setup Material Flow
I
l y
n
t
O n
e
r
n
r
a
e
1. Warehouse Layout
l
n
t
U
2. Routing
r
s
a
3. Task Creation
e
P
S A P
4. Task Communication
S A P
P a
6. Capacity Management
s e
r
7. Exceptions
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
I
l y
n
t
O n
e
r
n
r
a
e
l
n
t
U
r
s
a
e
P
S A P
S A P
CP
P a
s e
r
U
t
Confirm task CP01-CP02
Create new task CP02 – CP11
n
l
e
a
r
n
r
O
e
n
t
l
n
y
WTCO HU 1 from CP01 to CP02 WT HU1 from CP02 to CP11
I
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
I
l y
n
MFS Action Function Module Mandatory Meaning and Function
t
O n
Fields
e
r
n
r
a
/SCWM/MFSACT_LOC_EMPTY CP, SOURCE HU has left its source location.
e
l
HU
• Retrieves one or all WT(s) starting at this CP and previously sent to the PLC.
n
t
U
• Sets WT subsystem state to “W” (has left source)
r
s
a
e
P
S A P
S A P
P a
• If a product is assigned to the bin, replenishment is triggered
s e
r
U
t
/SCWM/MFSACT_SP CP, HU, HU has been scanned at identification point.
n
MFS_ERROR
l
e
• Posts HU to CP
a
r
Precondition: HU logically located at (any) CP or open WT to (any) CP
n
O
e
n
t
l
• Checks exceptions ( clearing)
n
y
I
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
I
l y
n
Consider material flow restrictions during BAdI „Identification Point Processing“
t
O n
e
capacity restrictions)
r
n
r
a
e
l
BAdI „Identification Point Processing“
n
U
r
s
a
e
P
S A P
S A P
HU errors detected by the PLC (noread, Customize exceptions matching PLC error codes
outline, overweight, HU type)
P a
s e
r
BAdI „Identification Point Processing“
U
Verify HU weight
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
I
MFS Action Function Module Mandatory Function
l y
n
Fields
t
O n
e
r
n
r
/SCWM/MFSACT_STATUS Equipment ID Equipment State has changed (CP, segment, segment group,
a
e
l
n
segment group
• Changes state of equipment
t
U
resource),
r
s
a
material flow)
e
P
S A P
S A P
P a
/SCWM/MFSACT_WT_CONFIRM CP, HU, HU has arrived at CP
s e
MFS_ERROR
• Posts HU to CP resp. storage bin (if not yet there)
r
U
t
• Triggers follow up task (layout oriented)
n
l
e
a
r
n
r
O
/SCWM/MFSACT_WT_CONFIRM_CANC CP, HU, PLC has confirmed or denied to cancel a task
e
n
MFS_ERROR
• Cancels the task (if MFS_ERROR isn‟t set)
t
l
n
y
I
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
Agenda
Setup Material Flow
I
l y
n
t
O n
e
r
n
r
a
e
1. Warehouse Layout
l
n
t
U
2. Routing
r
s
a
3. Task Creation
e
P
S A P
4. Task Communication
S A P
P a
6. Capacity Management
s e
r
7. Exceptions
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
Capacity Management
Customize Capacity Restrictions
I
l y
n
t
O n
e
r
n
r
a
e
l
n
t
U
r
s
a
e
P
S A P
S A P
P a
s e
r
U
t
n
l
e
a
r
The capacity is counted in number of HUs (disregarding their size).
n
O
The capacity exception controls the system behavior in case of lack of free capacity.
e
n
t
l
n
y
I
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
Capacity Management
Exception Settings
I
l y
n
Exception MCAP
t
O n
e
The exception has to be defined for the resp.
r
business context and execution environment:
n
Business context „Communication Point
r
a
e
l
n
U
r
s
a
e
P
S A P
S A P
P a
s e
r
U
t
nevertheless but not sent to the PLC
n
l
e
a
r
n
routes
r
O
NSND is recommended for resources
e
n
t
l
n
y
I
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
Capacity Management
Discharging Triggers (CP Dependencies)
I
l y
n
CR3
t
CR1
O n
TRR01
e
CR2
r
n
r
a
e
l
CP12 CP13 CP16 CP17 CP20 CP21
n
t
U
r
s
a
e
TCAR
Discharging Table
P
S A P
S A P
CP09
P a
s e
r
U
t
n
l
e
a
r
If there is a HU waiting on CP01 it
n
O
e
n
t
l
PLC.
n
y
WT confirmation message with source CP02
I
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
Capacity Management
Use Discharge Messages
I
l y
n
CR3
t
CR1
O n
TRR01
Check discharging table for entries for „CP11“
e
CR2
r
n
r
a
WT HU „1“ from „CP11“ to „CP12“ started (state „W“)
e
l
CP12 CP13 CP16 CP17 CP20 CP21
n
t
U
r
s
a
e
TCAR
P
S A P
S A P
CP09
P a
s e
r
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
LOCL CP11 1
I
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
Agenda
Setup Material Flow
I
l y
n
t
O n
e
r
n
r
a
e
1. Warehouse Layout
l
n
t
U
2. Routing
r
s
a
3. Task Creation
e
P
S A P
4. Task Communication
S A P
P a
6. Capacity Management
s e
r
7. Exceptions
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
Exceptions
Setup Reaction to Equipment Faults
I
l y
n
Two initiators for exceptions: CR3
t
CR1
TRR01
e
CR2
r
n
r
a
e
l
CP12 CP13 CP16 CP17 CP20 CP21
n
t
U
r
s
a
e
For both, exceptions must be allowed in exception customizing TCAR
P
S A P
S A P
CP09
P a
s e
r
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
Exceptions
Allow Supervisor and PLC to Set Equipment Faults
I
l y
n
Supervisor blocks communication point
t
O n
e
r
n
r
a
e
l
n
t
U
r
s
a
Business Context
e
„Communication Point“
P
S A P
S A P
P a
s e
r
Customizing exception MBLK
U
t
n
l
e
a
r
n
r
O
Execution Environment
e
n
t
-- A0 Background (PLC)
l
n
y
I
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
Exceptions
Equipment State Telegram
I
Customizing state telegram types and MFS action function
l y
n
t
O n
e
r
n
r
a
e
l
n
t
U
r
s
a
e
P
S A P
S A P
P a
s e
r
U
t
n
l
e
a
r
n
STAT CP02 01
r
O
e
n
t
l
n
y
CP „CP02“ state „not ready“ PLC
I
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
Exceptions
Conveyor Segments and Segment Groups
I
l y
n
CR3
t
CR1
O n
TRR01
e
CR2
r
n
r
a
e
l
CP12 CP13 CP16 CP17 CP20 CP21
n
t
U
r
s
a
e
TCAR
P
S A P
S A P
CP09
P a
s e
r
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
STAT GASSE1 XX
I
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
Exceptions
HU Related Exceptions
I
l y
n
CR3
t
CR1
O n
TRR01
e
CR2
r
n
r
a
e
l
CP12 CP13 CP16 CP17 CP20 CP21
n
t
U
r
s
a
e
TCAR
P
S A P
S A P
CP09
P a
s e
r
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
SCAN CP12 HU ? MFS_ERROR 90
I
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
Exceptions
Prepare Transport of Unknown HUs
I
l y
n
CR3
t
CR1
O n
TRR01
e
CR2
r
n
r
a
e
l
CP12 CP13 CP16 CP17 CP20 CP21
n
t
U
r
s
a
e
TCAR
P
S A P
S A P
CP09
P a
s e
r
U
t
Create new HU
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
Exceptions
Storage Bin Occupied
I
Define an exception code:
l y
n
t
O n
e
r
n
r
a
e
l
n
Assign internal
t
U
r
s
process code
a
e
BINO:
P
S A P
S A P
P a
s e
r
U
Assign an Alert:
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
PLC error code:
I
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
Exceptions
Storage Bin Occupied
I
l y
n
t
O n
e
Maintain follow-on action to block the occupied bin:
r
n
r
a
e
l
n
t
U
r
s
a
e
P
S A P
S A P
P a
s e
r
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
Exceptions
Storage Bin Occupied
I
l y
n
t
O n
e
Implement BAdI to determine a new destination bin:
r
n
r
a
e
l
n
t
U
r
s
a
e
P
S A P
CR3
S A P
CR1
TRR01
CR2
P a
s e
r
CP12 CP13 CP16 CP17 CP20 CP21
... and / or setup default storage bin:
U
t
n
l
e
a
r
TCAR
n
CP01 CP10
CP02 CP03 CP05 CP07
(IP)
r
(IP)
O
e
n
t
l
(PP)
n
y
CP09
I
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
Exceptions
Bin Empty
I
Define an exception code and assign internal process code BINE :
l y
n
t
O n
e
MBNE
r
n
r
a
e
l
n
t
U
r
s
a
e
P
S A P
S A P
P a
s e
r
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
PLC error code:
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© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y
I n t e r n a l U s e S A P P a r t n e r O n l y
Exceptions
Bin Empty
I
l y
n
t
O n
e
Maintain follow-on action to block the empty bin:
r
n
r
a
e
l
n
t
U
r
s
a
e
P
S A P
S A P
P a
s e
r
U
t
n
l
e
a
r
n
r
O
e
n
t
l
n
y
I
© SAP 2010 I n t e r n a l U s e S A P P a r t n e r O n l y