I 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

SAP EWM 210_1

P a
s e

r
U

t
n
Material Flow System
l

e
a

r
n
r

O
e

Overview

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

SAP EWM Extended Warehouse Management

Curriculum

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

SAP Service Parts Extended Warehouse Extended Warehouse Additional Features in

l
Management Management Management Extended Warehouse
n

Overview Customizing Management

t

U
r

s
a

e
EWM210 3h
P

Material Flow System

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

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

4. Which kind of equipment may be integrated and which not?

P a
s e

5. How complicated is it to implement it?

r
U

t
n
6. How can it be tested?
l

e
a

r
n

7. What should be considered when deciding for MFS?

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

Business Needs Addressed by MFS

Customer Perspective

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

without needing an external material flow

t

U
r

system

s
a

e
P

SAP WM SAP EWM

 Reduce the number of interfaces

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

Business Scenario – High Rack Warehouse for

Pallets
Aisle 1 Aisle 2 Aisle 3

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

ID Point Put away Removal-HU

r

O
Put away Pick-HU
e

n
t

l
n

y
I

Pick Point
Full pallets
Pick-HU

Goods Receipt Clearing Goods Issue Empty Pallets

I 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

Requirements – ID Point

Aisle 1 Aisle 2 Aisle 3

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

ID Point Put away Removal-HU

HU Type?
r

O
Put away Pick-HU
e

n
HU
t

l
n

y
warehouse
I

conform? Pick Point

Full pallets
Pick-HU

Goods Receipt Clearing Goods Issue Empty Pallets

I 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

Requirements – Cranes

Aisle 1 Aisle 2 Aisle 3

I
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

Crane1 Drop point

available?

P a
s e

r
U

t
n
Conveyor System
TCAR
l

Transfer Car

e
a

r
n

ID Point Put away Removal-HU

r

O
Put away Pick-HU
e

n
t

l
n

y
I

Pick Point
Full pallets
Pick-HU

Goods Receipt Clearing Goods Issue Empty Pallets

I 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

Requirements – Transfer Car

Aisle 1 Aisle 2 Aisle 3

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

Task Interleaving. ID Point Put away Removal-HU

r

O
Put away Pick-HU
Task priorities.
e

n
t

l
Drop point
n

y
I

available? Pick Point

Full pallets
Pick-HU

Goods Receipt Clearing Goods Issue Empty Pallets

I 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

Requirements – Capacity Event Triggering

Aisle 1 Aisle 2 Aisle 3

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

ID Point HU 1 Put away Removal-HU

r

O
Put away Pick-HU
e

n
t

l
n

y
I

Pick Point
Full pallets
Pick-HU

Goods Receipt Clearing Goods Issue Empty Pallets

I 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 Scenario –
Programmable Logic Controllers (PLC)

I
l y

n
Crane3

t
O n

e
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

• Consider physical capacity of resources (CP,

l
n

conveyor segment, transfer car, crane)

t

U
r

• Consider physical / logical state of resources (out

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

r
n

• Real time control of drives

r

O
e

• Keep track of HUs from CP to CP

n
t

l
• Read scanners
n

y
I

• Support HU compliance check

(measure HU outline, measure HU
height, read weight from scale,
detect HU type) CP = Communication Point
I 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

EWM Controls Single Transportation Steps

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

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
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

EWM Controls Single Transportation Steps

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

Final

S A P
Destination
S A P

CP12

Intermediate

P a
s e

Destination CP11

r
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

EWM Controls Single Transportation Steps

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
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

EWM Controls Single Transportation Steps

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

EWM Controls Single Transportation Steps

I
Aisle 1 Aisle 2
l y

n
t
O n

e
EWM Final

r
Destination

n
r

a
e

l
n
t

U
r

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
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

Documents during HU Transportation

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

Telegram 4 from PLC (Task Conf.)

r
n

1
r

O
Activation Warehouse Task 1
e

n
t

l
Telegram 5 to PLC (Task)
n

y
I

Telegram 6 from PLC (Task Conf.)

I 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

 Response time around 1 sec*

a
e

l
n

Two transactions per event

t

U
Confirm previous task (post HU to new bin)
r

1.

s
a

e
2. Create / select and communicate follow-up task**
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
* 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

4. Which kind of equipment may be integrated and which not?

P a
s e

5. How complicated is it to implement it?

r
U

t
n
6. How can it be tested?
l

e
a

r
n

7. What should be considered when deciding for MFS?

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

MFS Uses and Extends Existing EWM Objects

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

MFS Telegrams are Created for

Subsystem Relevant Queues

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

Area Process Type Area

a
e

Activity

l
n

Queue determination is
t

U
customizable
r

s
a

e
P

Queue Determination Criteria

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

Queues are PLC

r

O
CONV01
relevant by customizing
e

n
RSRC03
t

l
n

y
I

CONSYS1 CONSYS2 PLC or other sub system

I 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

PLC Telegrams Trigger MFS Function Modules

which Make Use of Standard EWM Coding

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

Confirm task CP01-CP02

t
Create new task CP02 – CP11

n
l

e
a

r
n
r

O
e

n
t

WT HU1 from CP02 to CP11

l
WTCO HU 1 from CP01 to CP02
n

y
I

HU 1 arrives at CP02 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

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

Alerts & Application Log

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

Lesson 2 - MFS Integration

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

 Background warehouse task execution with automated equipment

l
n
t

U
r

s
a

 Advantage

e
P

 Every EWM data available

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

 Performance and / or response times may be an issue

I 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

4. Which kind of equipment may be integrated and which not?

P a
s e

5. How complicated is it to implement it?

r
U

t
n
6. How can it be tested?
l

e
a

r
n

7. What should be considered when deciding for MFS?

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

MFS uses EWM Layout Oriented Storage

Control

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

From ... to ... via

n
r

a
e

Conveyor System
TCAR Transfer Car

l
ID Point Put away Removal-HU
n

Put away Pick-HU

t

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

Layout Oriented Storage Control Allows

Automatic Reaction to Material Flow Errors

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

New way is determined

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

Material Flow Attributes are Extensions to

Storage Bins

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

Communication Point (CP).*

a
e

l
n

 Communication points are linked to storage bins (master data).

t

U
r

 The main CP attributes are

s
a

e

P

Capacity (number of HUs allowed at this location at a time)

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

*also called “Reordering Point”

I 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 Interface - not IDOCs

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

info except telegram type)

e
P

SAP EWM SAP EWM

 Fast

S A P
S A P

 No RFC library for PLCs available

 Best practice for warehouse automation EWM-WCU IDOC

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

PLC Communication Protocol is Part of EWM –

Not of an External Communication Layer
Sender repeats a message as long as it isn„t acknowledged (every n secs.)

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

Send buffer Channel 1

l
n

No Telegram Snd Ack

t

U
17 State Request CP13 Y N
r

s
TASK CP02 – CP03
a

18 N N Last No. received 923

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

Last No. received 17 Send buffer Channel 1

r

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

Receiver sends an acknowledge message for every message he receives

Receiver processes a message only the first time he receives it

I 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

Systems are Connected via RFC Adapter:

“SAP Plant Connectivity” (SAP PCo)

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

and registers to SAP as an external RFC

l
n

destination (transaction SM59, RFC)

t

U
r

• This adapter doesn’t convert data. It simply

s
a

e
sets the data to another “rail”.
P

• It doesn’t keep track of the data. It doesn’t

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

• PLC IP addresses and ports are maintained

t
n
in EWM and passed to the adapter during
l

e
a

startup.

r
n

• For scalability reasons it is possible to use a

r

O
e

n
PLC separate adapter instance per warehouse
t

l
number and PLC.
n

y
I

• The RFC-Adapter from SAP is called „SAP

Plant Connectivity“ (SAP PCo) and it runs
on Windows systems.

I 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

Interface to Connect non-SAP RFC Adapters

Available

I
l y

n
SAP PCo is restricted to

t
O n

e
 Windows OS

r
n
r

 No binary data in telegrams

a
e

l
n

 Telegram length < 256 byte

t

U
r

If PCo cannot be used an interface is foreseen to connect other adapters:

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

Telegram Communication Implementation

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

(/SCWM/MFSDELAY). If yes it adds the telegram to the buffer.

l
n

 If then an acknowledgement telegram is received for a previous telegram, the receiving

t

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

 PLC channels are started manually from the warehouse monitor.

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

The telegrams of each Channel A Channel C Channel B Channel D

t

U
channel are transmitted
r

s
a

e
sequentially.
P

S A P
S A P

RFC RFC RFC RFC

Data transmission and

P a
data processing are
s e

decoupled by the

r
U

t
database.

n
l

e
a

r
n

The telegrams of each Function Function Function Function

r

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

MFS Coding Refers to an Overall Telegram

Structure

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

(subset for project)

r
U

t
n
l

e
a

r
n
r

O
e

n
t

l
n

y
I

Customer append structure for

non-standard telegram fields
I 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 Add-Ins Allow to Manipulate

Telegrams Close to the Interface

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 Allows to Invoke Non-Standard

Processing of PLC Telegrams

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

•Call /SCWM/MFSACT_WT_CONFIRM with exception

r

O
e

n
WTCO HU 1 HB01-02-07-04
t

AOUT

l
n

y
PLC telegram
I

HU 1 not available for outbound request PLC1

I 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

Predefined Standard Telegram Types

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

WT Warehouse Task (HU from - to) LL Location Left

e
P

TC Warehouse Task Confirmation

S A P
S A P

CR Cancel Request for WT CA Cancel Response success / denied

SR State Request for CP / Resource ST State Message for CP / Resource
SC Scanner Message (HU at CP)

P a
LF Life Check Telegram LF Life Check Telegram
s e

SY Synchronization Request SB Synchronization Begin

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

Telegram Types and Telegram Structures

Customizable

I
l y

n
t
Assign telegram type identifiers to
O n

e
predefined telegram categories

r
n
r

Assign telegram type specific

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

Lesson 3 – Basic Concepts

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

 Extendable overall telegram structure

a
e

l
n

 Flexible method invocation

t

U
r

 Be able to move exceptional HUs (unknown, no destination)

s
a

e
P

 Spread of responsibilities between EWM and PLC is flexible

S A P
S A P

 Standard functions* available for

 Warehouse task execution

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

4. Which kind of equipment may be integrated and which not?

P a
s e

5. How complicated is it to implement it?

r
U

t
n
6. How can it be tested?
l

e
a

r
n

7. What should be considered when deciding for MFS?

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

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

Printers, label applicators at conveyors – coding required

t

U

r

s
 HU sorters – depending on performance requirements
a

e
P

 Resources

S A P
S A P

 Cranes – single load

 Transfer cars – single load

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

Lesson 4 – Kinds of Equipments which may be

integrated

I
l y

n
t
O n

e
r
First approach:

n
r

HU task handling systems – communicate single warehouse tasks via MFS-PLC

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

4. Which kind of equipment may be integrated and which not?

P a
s e

5. How complicated is it to implement it?

r
U

t
n
6. How can it be tested?
l

e
a

r
n

7. What should be considered when deciding for MFS?

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 Steps for PLC Link

I
l y

n
1. Define telegram structure

t
O n

e
r
2. Define interface type

n
r

a
e

3. Define telegram types and structures

l
n
t

U
r

4. Define PLC

s
a

e
P

5. Define communication channel for PLC

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

9. Maintain communication channel: Assign IP address and port

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

Customizing Steps for Material Flow

with Conveyor Systems

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

5. Customize capacity restrictions

S A P
S A P

6. Setup reaction to equipment faults

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

Customizing Steps for Material Flow

with Resources

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

1. Create high bay storage bins

S A P
S A P

2. Layout oriented storage control

3. Setup PLC and channel for the automated storage retrieval machines

P a
4. Define WT queues and queue determination criteria
s e

5. Define a resource type and create resources

r
U

t
6. Control interleaving (dual cycle movement for rack feeders)

n
l

7. Setup exception handling „Bin occupied“

e
a

r
n

8. Setup exception handling „Bin empty“

r

O
e

3. Stock removal in an automated warehouse

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

4. Which kind of equipment may be integrated and which not?

P a
s e

5. How complicated is it to implement it?

r
U

t
n
6. How can it be tested?
l

e
a

r
n

7. What should be considered when deciding for MFS?

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

Test with Physical Equipment is Expensive

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

 It is more complicated to prepare all three for a test

t

U
r

s
 Different parties have to wait for each other (especially in case of errors)
a

e
P

 Reduced test slots with physical equipment.

S A P
S A P

 No remote test with physical equipment.

 Load test needs a lot of preparation.

P a
s e

 If it is an existing warehouse (retrofit), additional issues for testing are

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

Not only before but also after going live.

I 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

Test Tool SAP PLC Emulation

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

• Allows forcing errors.

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

• Important quality factor.

e
P

• Is a service provided by SAP Consulting (not a SAP AG

S A P
S A P

product) SAP EWM SAP EWM

• To be calculated on top of MFS implementation.
SAP MFS SAP MFS

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

Real Life Test Scenarios

Example Goods Receipt Scanner

I
l y

n
t
Scanner 01SC0001Goods Receipt
O n

e
r
n
r

a
e

l
n

Create error message

t

U
Check HU OK? No Set HU exception
(height / weight)
r

HU moved to

s
EWM

Yes Post HU to WE02

WE02?
a

e
P

Yes

S A P
No
Teletype 51 Teletype 51 HU has exception
No Set HU exception DAS
S A P

Destination WE02 Destination WE01 already?

(Sorter) (Clearing)

Teletype 04

P a
HU 12345678 Teletype 11
s e

Height 01/02 DAS report

Weight 20,00kg

r
PLC
U

t
n
l

Collect weight, Control Conveyor Create DAS report

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

Performance Test with SAP PLC Emulation

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

Simulation versus Emulation

I
l y

Simulation is a design test tool.

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

Emulates WMS-PLC interface.

O
Simulates material flow.
e

n
t

l
Focus Focus
n

y
I

Determine bottle necks during Test WMS during warehouse

warehouse design. implementation and maintenance.
Adjust strategies.

I 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

 Parallel testing (different warehouse numbers, different areas)

t

U
r

 Reduce risk for maintenance as well (process changes, notes, releases)

s
a

e
P

 SAP PLC emulation

S A P
S A P

 Flexible core available

 CSV table based (allows a lot of customizing including layout)

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

4. Which kind of equipment may be integrated and which not?

P a
s e

5. How complicated is it to implement it?

r
U

t
n
6. How can it be tested?
l

e
a

r
n

7. What should be considered when deciding for MFS?

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

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

Non standard equipments Risk

P a
7*24h
s e

e.g. label applicators, robots Time / Cost

r
U

t
n
l

e
a

r
n

Non standard
r

High Volume

O
communication protocol
e

n
t

l
n

y
I

Multi HU forks / multi deep

I 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

SAP EWM 210_2

P a
s e

r
U

t
n
Material Flow System
l

e
a

r
n
r

O
e

Setup PLC Communication

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

SAP EWM Extended Warehouse Management

Curriculum

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

SAP Service Parts Extended Warehouse Extended Warehouse Additional Features in

l
Management Management Management Extended Warehouse
n

Overview Customizing Management

t

U
r

s
a

e
EWM210 3h
P

Material Flow System

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

1. Setup MFS PLC Communication Protocol

l
n
t

U
2. Maintain PLC master data
r

s
a

3. Internal Test with /SCWM/MFS_SIM_RECEIVE

e
P

S A P
4. Setup SAP PCo
S A P

5. Setup PLC Emulation Tool

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

TELE PLC PLC Link

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

EWM Telegram Categories

Protocol Related / Material Flow Related
Usage

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

 STAT  Status Message  PLC to indicate that an equipment is temporarily not

P a
available resp. available again
s e

 WT  Warehouse Task  EWM to give an order to the PLC to move a HU

r
U

t
n
 WTCO  Warehouse Task Confirmation  PLC to indicate that a task has been executed
l

e
a

r
n

 LOCL  Location Left  PLC to indicate that a HU has left a location

r

O
e

n
t

 WTCR  Cancellation Request  EWM to cancel a warehouse task

l
n

y
I

 WTCC  Cancellation Response  PLC to respond to a cancellation request from EWM

 SCAN  Scanner Message  PLC to announce a HU at a location

© 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

EWM connects to the PLC

t

U
EWM initates the communication process
r

s
by sending a synchronization request Sync Begin
a

e
P

S A P
S A P

... buffered telegrams ...

P a
s e

EWM accepts all outstanding messages

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

(Acknowledgment telegrams are not shown)

© 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
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

Both sides accept

a new telegram

P a
while waiting for an
s e

acknowledgement Ack 1 Ack 1

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

Telegram Repetition Process (Batch Job):

t

U
• Checks for outstanding ack. telegrams
r

s
Tele 2
a

• Repeats telegrams n time with the same

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

• Is responsible for all channels within warehouse

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

Customizing Steps for PLC Link

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

Indicates to the receiver if the telegram has been received before

s
 If one of these fields is missing in a given protocol
a

e
– Handshake flag BAdIs have to be implemented (manipulation of
P

Data or acknowledgement telegram telegrams for sending / receiving)

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

Define Telegram Structures

Based on /SCWM/S_MFS_TELETOTAL

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

Customizing Steps for PLC Link

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

Two Ways to Assign Structures to PLCs

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

Define Interface Types

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

Interface Type Interface Type

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

Note: Telegram Types are just

P a
identifiers for telegram categories.
s e

They can be freely defined with the

r
U

PLC vendor (max. 4 char).

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

Customizing Steps for PLC Link

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

Define PLC and Assign Header Structure

The header structure is used for the

I
PLC
l y

n
communication protocol and to indicate

t
O n

scope and structure of the telegram to the

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

© SAP 2010 / Page 18 I 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

PLC Customizing

I
l y

Every external system, which should be

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

 Don’t set here, set WPT on CP level at ID-Point

t

U
r

 Process Type Fault:

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

 Exception Code MFS:

Is used to control the reaction in case of flow error.
 Use an exception code creating an alert and triggering

P a
s e

internal process code CHBD.

r
 will post the HU to the new location and make this
U

t
exception visible to the supervisor

n
l

 Mapping:

e
a

Controls if the mapping table is used to map EWM

r
n

storage bin names to PLC addresses.

r

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

incoming telegrams, if customizing flag “check telegram”

is set in communication channel customizing.

© 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 Channel Customizing

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

 Don’t use fill characters

a
e

 may not work in every situation

l
n

 Set handshake identifiers

t

U
 otherwise BAdI must be implemented
r

s
a

Use handshake mode “send complete telegram”

e

P

 eases programming on PLC side

S A P
S A P

 Use life telegrams

 connection loss will be detected automatically
 Activate Get Sequence Numbers for life telegrams

P a
 no exceptional coding needed
s e

 Use an end character

r
U

 will ease reading the log

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

Customizing Steps for PLC Link

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

Standard Exceptions and PLC Error Codes

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

Match EWM Exceptions to PLC Errors:

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

What does it mean if the PLC sends error „90“?

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

1. Setup MFS PLC Communication Protocol

l
n
t

U
2. Maintain PLC master data
r

s
a

3. Internal Test with /SCWM/MFS_SIM_RECEIVE

e
P

S A P
4. Setup SAP PCo
S A P

5. Setup PLC Emulation Tool

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

Maintain Master Data and RFC

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

PLC Interface Settings

I
l y

n
IMG Master Data

t
O n

e
r
n
r

a
e

l
n

PLC TeleStructHeader PLC CommLayer

t

U
Except. Deviation RFC Destination
r

s
a

Tele Logging

e
Activate Mapping
P

Interface Type TeleType

S A P
S A P

Fault Process Type TeleStruct

Bin Mapping
Sender Ident EWM Tele Err Codes

P a
s e

r
U

t
n
l

Channel Sequ No range Channel IP / Port

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

Create 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

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

Maintain Communication Channel

Assign IP Address and Port

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

Connect RFC Adapter

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

The adapter registers the program ID in SAP Logon

RFC-Adapter
r

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
..

PLC I love you,

Me too
CONSYS1

© 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

1. Setup MFS PLC Communication Protocol

l
n
t

U
2. Maintain PLC Master Data
r

s
a

3. Internal Test with /SCWM/MFS_SIM_RECEIVE

e
P

S A P
4. Setup SAP PCo
S A P

5. Setup PLC Emulation Tool

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

Internal Test with

/SCWM/MFS_SIM_RECEIVE

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

Internal Test with

/SCWM/MFS_SIM_RECEIVE

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

 Warehouse Task Confirmation

s
a

e

P

Warehouse Task Cancellation

S A P
 Customizing is used
S A P

It does not include:

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

1. Setup MFS PLC Communication Protocol

l
n
t

U
2. Maintain PLC Master Data
r

s
a

3. Internal Test with /SCWM/MFS_SIM_RECEIVE

e
P

S A P
4. Setup SAP PCo
S A P

5. Setup PLC Emulation Tool

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

 Product Information available in the service market place:

e
P

http://www.sap.com/solutions/manufacturing/index.epx

S A P
S A P

 Requires Microsoft .NET Framework 3.5 Service Pack 1.

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

SAP Plant Connectivity

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

SAP PCo 2.0, 2.1

O
Instance“
e

„Source Channel“

n
t

l
n

y
I

Socket Server

Java PLC Emulation SYES

SYBE
SYEN
LIFE
LIFE

© 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

Configuring PCo Source System

I
l y

PCo

n
t
O n

Source System Agent Instance Destination System

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

Configuring PCo Destination System

I
l y

PCo

n
t
O n

Source System Agent Instance Destination System

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

Configuring PCo Agent Instance

I
l y

n
PCo

t
O n

Source System Agent Instance Destination System

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

Configuring PCo Agent Instance

I
l y

n
PCo

t
O n

Source System Agent Instance Destination System

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

Configuring PCo Agent Instance

I
l y

n
PCo

t
O n

Source System Agent Instance Destination System

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

1. Setup MFS PLC Communication Protocol

l
n
t

U
2. Maintain PLC Master Data
r

s
a

3. Internal Test with /SCWM/MFS_SIM_RECEIVE

e
P

S A P
4. Setup SAP PCo
S A P

5. Setup PLC Emulation Tool

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

PLC Emulation Tool

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

 Telegram structure body

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

local csv files

© 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

Emulation Settings - Ports & Telegram Types

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

Maintain telegram header structure

P a
s e

r
U

t
n
l

e
a

r
n
r

O
e

n
t

l
n

y
I

Maintain telegram body structure

© 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

Start PLC Emulation

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

Choose project and version:

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

Start PLC Emulation

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

SAP EWM 210_3

P a
s e

r
U

t
n
Material Flow System
l

e
a

r
n
r

O
e

Setup Material Flow

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

SAP EWM Extended Warehouse Management

Curriculum

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

SAP Service Parts Extended Warehouse Extended Warehouse Additional Features in

l
Management Management Management Extended Warehouse
n

Overview Customizing Management

t

U
r

s
a

e
EWM210 3h
P

Material Flow System

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

5. PLC Event Processing

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

Define a separate storage type for final and for intermediate

n
storage locations and assign appropriate role.

t
O n

 Warehouse Monitor separates MFS relevant WTs and HUs.

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

CP12 CP13 CP16 CP17 CP20 CP21

S A P
S A P

CP11 CP14 CP15 CP18 CP19 CP22

P a
s e

Intermediate storage locations (conveyor system): TCAR

• Storage type role „H“: Automatic Storage Retrieval

r
U

CP01 CP10

t
CP02 CP03 CP05 CP07
(IP) (IP)

n
l

e
a

r
CP08
n

CP00 CP04 CP06

(PP)
r

O
e

CP09

n
t

l
n

y
I

“E”: Work Center Clearing

© 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

location has to be modeled as Storage Bin

t

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

storage bins for

• MFS capacity (number of HUs) Communication CP11 CP14 CP15 CP18 CP19 CP22

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

CP00 CP04 CP06

(PP)
r

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

FIFO (see next

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

WT for HU 2 will only be sent to the PLC after

t

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

Logical HU sequence will not be considered

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

• pack material to scanners (for “UFOs”)

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

send a put away task Number of tasks

r

O
after a retrieval task and that are optimized
e

n
vice versa by the PLC itself
t

l
n

y
I

Task and task

confirmation
telegram sequence

One queue Default destination in

per resource case of error “bin
occupied”
© 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
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

• Segments are checked to be available regarding

t

U
capacity and equipment fault during task execution
r

s
a

e
• Segment can be blocked by
P

Segment CP12 CP13 CP16 CP17 CP20 CP21

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

with a single PLC telegram

r
CP08
n

CP00 CP04 CP06

(PP)
r

O
e

CP09

n
t

l
• Recommendation:
n

y
I

Try to model the layout in MFS with help of CPs first.

Use segments if CPs aren‟t sufficient. Clearing

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

5. PLC Event Processing

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

• Are a means to control layout oriented routing

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

Storage Control Group

l
n

GR01 (CP, Storage Control Group, storage bin.

y
I

Storage Control Group is 4 bytes only.)

Goods Reception Storage Control Group
RCK2

© 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

Bin 1 Bin 2 Bin n Final Bin

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

Bin 1 Bin 2 Bin n Final Bin

* Sub second response time requirement

© 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
Fast* Routing Option (NL Development)

I
Product WT
l y

n
Product Requirement inactive active

t
HU Final Bin
O n

Product WT from HU to final bin

e
Activity Area1

r
n
r

At Scanner:

a
e

1. Receive sort request Scanner 1 Scanner 3

l
Scanner 2
n

2. Send sort instruction  “LEFT”  “CHUTE1”  “LEFT”

t

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

bin representing an area “Conv1” “LOOP1” “WS_AA1”

P a
s e

• Routing decision taken from a Z-Table Z Routing Table (Customizing)

r
Decision Logistical PLC Data After
• Based on logistical destinations
U

t
Point Destination Destination Sorting

n
• Logistical destinations determined by CP specific
l

Scanner 1 REJECT RIGHT CLEARING

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

Scanner2 Activity Area 2 CHUTE2 LOOP2

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

* < 0.5sec response time requirement, high volume

© 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 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

Layout-oriented storage control is not taken into account

© 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

CP12 CP13 CP16 CP17 CP20 CP21

e
P

S A P
CP11 CP14 CP15 CP18 CP19 CP22
S A P

TCAR

CP02 CP01 CP10

CP03 CP05 CP07
(IP) (IP)

P a
s e

CP00 CP04 CP08

CP06
(PP)

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

CP12 CP13 CP16 CP17 CP20 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

CP00 CP04 CP08

CP06
(PP)

CP09

P a
s e

r
U

t
n
l

e
a

r
n

Partial stock removal:

r

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

Outbound Delivery CR3

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

CP12 CP13 CP16 CP17 CP20 CP21

Stock

l
n

 HU 65: 1000 kg Prod A  full movement

t

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

CP00 CP04 CP08

CP06
 Product-WT and (PP)

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

CP00 CP04 CP08

CP06
(PP)

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

CP12 CP13 CP16 CP17 CP20 CP21

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

CP00 CP04 CP08

CP06
(PP)

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

CP12 CP13 CP16 CP17 CP20 CP21

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

CP00 CP04 CP08

CP06
(PP)

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 / Page 21 I 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
r
n
r

a
The inactive WT gets active if there is no further
e

CP12 CP13 CP16 CP17 CP20 CP21

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

Create new customer HU (101) at CP09

a
e

CP12 CP13 CP16 CP17 CP20 CP21

l
n
t

U
B) CP11 CP14 CP15 CP18 CP19 CP22
r

s
a

Drag quantity from storage HU 66 to customer HU 101 TCAR

e
P

CP01 CP10
confirms WT 78286 CP02
(IP)
CP03 CP05 CP07
(IP)

S A P
S A P

CP00 CP04 CP06

66
CP08
(PP)

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

CP12 CP13 CP16 CP17 CP20 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

CP00 CP04 CP06

66
CP08
(PP)

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

CP12 CP13 CP16 CP17 CP20 CP21

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

CP00 CP04 CP06

66
CP08
(PP)

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

D) Close the storage HU 66: A new WT to 0280 is created. CR2

e
r
n
r

a
e

CP12 CP13 CP16 CP17 CP20 CP21

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

CP00 CP04 CP06

66
CP08
(PP)

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

© SAP 2010 / Page 26 I 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
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

CP12 CP13 CP16 CP17 CP20 CP21

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

CP00 CP04 CP08

101
CP06
(PP)

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

5. PLC Event Processing

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 / Page 28 I 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
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

 1 WO may contain several WTs  1 WO contains just 1 WT

 1 WO is executed by 1 resource  1 WO is executed by 1 resource or a PLC directly
 1 resource may execute WOs from several queues  1 resource executes WOs from just 1 queue
 Several resources may execute several queues  1 PLC may execute several queues via different resources
and another one directly
© SAP 2010 / Page 29 I 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 and Queue Determination

I
l y

n
t
O n

e
r
CP CP

n
r

a
e

Storage Bin Storage Bin

l
n
t

U
r

s
a

e
P

S A P
S A P

Warehouse Task

P a
s e

Queue Determination Criteria Warehouse Order Creation Rule

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

Sort Sequence Sort Sequence

Order Creation Rule Act. Area / Activity
Act. Area / Activity

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

Determine queue by bin access type and activity

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

5. PLC Event Processing

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

 SYBE  Synchronization Start  PLC to start synchronization mode (answer to SYES)

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

 STAT  Status Message  PLC to indicate that an equipment is temporarily not

P a
available resp. available again
s e

 WT  Warehouse Task  EWM to give an order to the PLC to move a HU

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

 WTCC  Cancellation Response  PLC to respond to a cancellation request from EWM

 SCAN  Scanner Message  PLC to announce a HU at a location

© 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

• Location left (optional)

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

• State request (optional)

r

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

• Start Confirmation (optional)

t

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

• State request (optional) … same as conveyors

r

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

5. PLC Event Processing

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

PLC Event Processing

Assign MFS Action FMs to Telegram Types

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

HU 1 arrives at CP02 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

PLC Event Processing

Standard MFS Action Function Module

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

• Capacity of the source increases

e
P

• Checks communication point dependencies (trigger subsequent flow)

S A P
S A P

/SCWM/MFSACT_REPLENISH CP, SOURCE Fixed bin is empty.

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

exists. Otherwise Dummy HU is created and sent to clearing

r

O
e

• Cancels any open WT for the HU

n
t

l
• Checks exceptions ( clearing)
n

y
I

• Updates HU: HU type, weight, volume, length, width, height

• Triggers put away strategy ( BAdI needs to be implemented!)
• Creates follow-up task (layout-oriented)

© 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

PLC Event Processing

Additional Requirements at ID Point

I
l y

n
Consider material flow restrictions during BAdI „Identification Point Processing“

t
O n

putaway strategy (unavailable equipment /

e
capacity restrictions)

r
n
r

a
e

l
BAdI „Identification Point Processing“
n

Aisle load balancing

t

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

Accept new HU type By default

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

PLC Event Processing

Standard MFS Action Function Module

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

(CP, Segment, resource).

l
n

segment group
• Changes state of equipment
t

U
resource),
r

MFS_ERROR • Checks communication point dependencies (triggers subsequent

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

5. PLC Event Processing

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

 Each communication point may have a maximum capacity assigned.

e
a

r
 The capacity is counted in number of HUs (disregarding their size).
n

 If a maximum capacity is entered, a capacity exception has to be assigned.

r

O
 The capacity exception controls the system behavior in case of lack of free capacity.
e

n
t

l
n

 For capacity restriction conveyor segments may be used as well.

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

 Business context „Segment“

l
n

 Execution environment „Background“

t

U
r

s
a

e
P

S A P
S A P

Internal Process Codes available for Capacity

Restriction:

P a
s e

 STAY – the next warehouse task isn„t created

 NSND – the next warehouse task is created

r
U

t
nevertheless but not sent to the PLC

n
l

e
a

STAY is recommended, if there are alternate

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

CP11 CP14 CP15 CP18 CP19 CP22

s
a

e
TCAR

Discharging Table
P

CP02 CP01 CP10

CP03 CP05 CP07
(IP) (IP)

S A P
S A P

CP00 CP04 CP08

CP06
(PP)

CP09

P a
s e

r
U

t
n
l

e
a

r
If there is a HU waiting on CP01 it
n

will be checked, if now a WT can

r

O
e

Discharge Event for CP02 be created and / or be sent to the

n
t

 WT start message with source CP02

l
PLC.
n

y
 WT confirmation message with source CP02
I

 State message „ready“ for CP02

 WT cancellation with destination CP02

© 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

CP11 CP14 CP15 CP18 CP19 CP22

s
a

e
TCAR
P

CP02 CP01 CP10

CP03 CP05 CP07
(IP) (IP)

S A P
S A P

CP00 CP04 CP08

CP06
(PP)

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

HU „1“ has left CP „CP11“ 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

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

5. PLC Event Processing

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

User and PLC

O n

TRR01

e
CR2

r
n
r

a
e

l
CP12 CP13 CP16 CP17 CP20 CP21
n
t

U
r

CP11 CP14 CP15 CP18 CP19 CP22

s
a

e
For both, exceptions must be allowed in exception customizing TCAR
P

CP02 CP01 CP10

CP03 CP05 CP07
(IP) (IP)

S A P
S A P

CP00 CP04 CP08

CP06
(PP)

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

-„A1 Desktop“ (Warehouse Monitor)

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

State = <space>, _ or 0 means “OK”

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

CP11 CP14 CP15 CP18 CP19 CP22

s
a

e
TCAR
P

CP02 CP01 CP10

CP03 CP05 CP07
(IP) (IP)

S A P
S A P

CP00 CP04 CP08

CP06
(PP)

CP09

P a
s e

Set PLC State

r
U

t
n
l

e
a

r
n
r

O
e

n
t

l
n

y
STAT GASSE1 XX
I

Segment group „GASSE1“ state „XX“ 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

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

CP11 CP14 CP15 CP18 CP19 CP22

s
a

e
TCAR
P

CP02 CP01 CP10

CP03 CP05 CP07
(IP) (IP)

S A P
S A P

CP00 CP04 CP08

CP06
(PP)

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

Noread at scanner „CP12“ 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

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

CP11 CP14 CP15 CP18 CP19 CP22

s
a

e
TCAR
P

CP02 CP01 CP10

CP03 CP05 CP07
(IP) (IP)

S A P
S A P

CP00 CP04 CP08

CP06
(PP)

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

Noread or unknown HU at scanner „CP12“

© 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

Invoke the exception as reaction to the

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

CP11 CP14 CP15 CP18 CP19 CP22

e
a

r
TCAR
n

CP01 CP10
CP02 CP03 CP05 CP07
(IP)
r

(IP)

O
e

n
t

CP00 CP04 CP08

CP06

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

Invoke the exception as reaction to the

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
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