SAP EWM MFS September2020
SAP EWM MFS September2020
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1
Overview
2
Functional
3
Customer
4
Frequently Asked
5
Related Topics /
Principles Examples Questions Outlook
1
Overview
2
Functional
3
Customer
4
Frequently Asked
5
Related Topics /
Principles Examples Questions Outlook
• You can define capacity limits for communication points, conveyer segments or resources.
The EWM system then holds back tasks for the PLC as soon as these limits are exceeded. The same
applies if the PLC reports that one of the individual elements of conveyance (vehicles, legs, communication
points) are subject to malfunction.
* PLC: Underlying realtime system controlling the physical transportation of HUs on conveyer systems and their components.
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What is SAP Material Flow System (MFS)?
Features
• Automatic identification of HUs using scanners on the automatic storage retrieval facility
• Automatic diversion of HUs that cannot be stored (incorrect contours, excessive weight, unidentified)
• Fully automatic putaway of HUs in the storage bin using any number of interim steps. Interim steps are
represented by communication points.
• Capacity limits for communication points, conveyer segments, and vehicles taken into account
• Stable telegram communication between EWM and PLC using parallel, bidirectional communication
channels
Business Benefits
→ Sophisticated strategies to consider physics
→ Higher transparency on processes
→ PLC link, material flow and monitoring in one central system
→ Scalable architecture
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Logical Layers in Automated Warehouses
Context
Warehouse equipment
Material Flow Control Detailed warehouse tasks
Plant Connectivity
TCP/IP
TCP/IP
SAP MFS is integrated within EWM and can be connected to one or more PLCs
Handling Warehouse
Unit task
PLC
relevant
Storage bin Storage bin
2 3
Devices HU 1
Resource
CP1 CP2 CP3
R1
Conveyers
• Pallets / cases / packages
• Transfer cars
• Sorter
• Label applicators
• Pick, pack & pass picking principle
Subsystems
• Monorail system
• Automated guided vehicle systems (AGV)
• Reduction of interfaces
• ONE responsibility for warehouse management SAP EWM SAP EWM
and material flow control (including
Material Flow
• Only SAP knowledge necessary System)
1
Overview
2
Functional
3
Customer
4
Frequently Asked
5
Related Topics /
Principles Examples Questions Outlook
SAP EWM
required (MFS) SAP EWM
SAP EWM
vendor selection
(including
• 3rd party dependence (including
Material Flow
System) Material Flow
System)
3rd party MFS
RFC
Plant Connectivity
TCP/IP
TCP/IP
Crane
3
PLC RACK3
Crane
Storing
2
PLC RACK2
Crane
1
PLC RACK1
SAP EWM
TCAR
PLC CONSYS1 IP
Picking
PP
Receiving GI
GR Clearing
Aisle 1 Aisle 2
EWM
Final
Destination
CP12
HU “1” at
Scanner “CP01” CP11
1
Scanner
CP02 CP01 TCAR1
Conveyer
PLC
Aisle 1 Aisle 2
EWM
Final
Move HU “1”
from “CP01” to “CP02” Destination
CP12
Intermediate CP11
Destination
1
Scanner
CP02 CP01 TCAR1
Conveyer
PLC
Aisle 1 Aisle 2
EWM
CP12
CP11
HU “1” arrived
at position “CP02”
1
Scanner
CP02 CP01 TCAR1
Conveyer
PLC
Aisle 1 Aisle 2
EWM
Move HU “1”
from “CP02” to “CP11”
with resource “TCAR1”
CP12
CP11
1
Scanner
CP02 CP01 TCAR1
Conveyer
PLC
Aisle 1 Aisle 2
EWM
CP12
Task Confirmation: 1
HU “1” at “CP11”
CP11
Scanner
CP02 CP01
TCAR
Conveyer
PLC
Aisle 1 Aisle 2
EWM
Task: HU “1”
from “CP11” to “CP12”
CP12
CP11
Scanner
CP02 CP01
TCAR
Conveyer
PLC
Aisle 1 Aisle 2
EWM
CP12
Task
Confirmation CP11
HU “1” at “CP12”
Scanner
CP02 CP01
TCAR
Crane1
PLC
Aisle 1 Aisle 2
EWM
CP11
Scanner
CP02 CP01
TCAR
Crane1
PLC
CP12
Task
Confirmation
HU “1” at “010201” CP11
Scanner
CP02 CP01
TCAR
Crane1
PLC
Material Flow
System)
PLC
P-Point
GI
GR NiO
Empty pallets
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Integrated Material Flow System
For direct control of automation – pick, pack & pass
SAP ERP /
S/4HANA CP
Sorter Decision
CP CP
GI Point
SAP EWM
(including
Material Flow
System)
Sorter Decision
CP CP
Point
GR
CP
TCP/IP
PLC Work
Center
Intermediate position
Start position End position
EWM
Typically
up to 1
sec.
PLC
Typically
up to 0,5
sec.
PLC
1
Overview
2
Functional
3
Customer
4
Frequently Asked
5
Related Topics /
Principles Examples Questions Outlook
Some Facts
• Location: Waldkirch, Germany
• > 48,000 products
• High bay warehouse with 6,600 pallet locations
and 4 aisles
• Small parts warehouse with 8 aisles and 117,000
locations for containers, 4-deep storage
• Shuttle warehouse with 7,200 locations
• Implementation partner: Salt
Some Facts
• Location: Elmshorn, Germany
• Integration of automatic high shelves into SAP
environment
• Double height pallets as storage unit
• 4 aisles pallet warehouse
• 5,600 pallet locations on 12 levels
• Implementation partner: Viastore Software
Some Facts
• Location: Baden-Baden, Germany
• Automated high bay warehouse for finished
goods
• Goods to person picking from automated
high bay
• 6,000 pallet locations in high bay warehouse
• Pick-by-light with 2,800 picks per day
• 86% increase in feedback response time
and 10% higher process efficiency overall
• Implementation partner: Aberle Software
GmbH
Some Facts
• Location: Heinsberg, Germany
• 10,000 sqm
• 5,500 products
• 21,000 storage bins
• Fully automated warehouse for buffering,
1,200 boxes, >300 double plays per hour
• Pick-by-voice
• Implementation partner: Aberle GmbH
and Aberle Software GmbH
Some Facts
• Location: Allendorf,
Germany
• Automated high-bay
warehouse with 19 aisles
• Automated mini-load
system with 2-deep
storage and 2 aisles
• Productivity increase in
picking and loading up to
10%
• Implementation partner:
inconso AG
Some Facts
• Location: Vanlor, Belgium
• Pallet warehouse with double deep bins (5 aisles,
16,000 bins)
• Two pallet spots on a crane (double stacker
cranes)
• Implemented by: SAP Consulting
Some Facts
• Location: Neckarsulm, Germany
• SAP MFS for pick, pack & pass
• Pick, pack & pass and putaway supported by
case conveyor
• 15,000 bins at conveyor systems
• 18 packing work center, 6 picking stations
• Implemented by: SAP Consulting
Some Facts
• Location: Austria
• High bay warehouse with 8,000 pallet locations
• 2 double deep aisles
• 3,000 locations in automatic small parts
warehouse
• Implementation partner: IGZ
“With the Proof of Concept, SAP has demonstrated the capability of EWM-MFS to handle the high performance requirements of the container handling
technology. During this „Sportive Challenge“, SAP showed its full commitment to take over responsibility in a project, delivered in partnership.”
Sven Bertelmann, Adolf Würth GmbH & Co. KG
Some Facts
• Location: Mexico
• no human intervention in the cross dock process
through the sorter
• Deconsolidation is done at the outlets of the
sorter
• Automated storage and retrieval system (ASRS)
• Layout oriented storage control
• > 125,000 telegrams processes in 10 hours (3.5
telegrams / second)
• 4,500 containers processes per hour
• Implementation partner: SAP Services
Link to slide deck: https://docplayer.es/19396308-Implementacion-sap-ewm-en-liverpool-sap-webinar-daniel-tapia-nosedal-gerente-centro-de-
competencias-area-logistica-18-de-noviembre-de-2015.html (Spanish only)
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Customer Example: Brose Fahrzeugteile SE & Co.
Automotive, world‘s fifth-largest family-owned automotive supplier
Some Facts
• Location: Koprivnice near Ostrava, Czech Republic
• Fully automated goods receipt warehouse for production supply
• Fully automated tugger train production supply
• 180 heavy load containers stored per hour by conveyors
• 5 aisle high bay warehouse
• 10,000 storage spaces in high bay warehouse
• Fully automated depalletizing by robot
• Automated small parts warehouse with 7 aisles, and 23,500 storage
spaces on 28 levels
• Implementation partner: SSI Schäfer, Swan
1
Overview
2
Functional
3
Customer
4
Frequently Asked
5
Related Topics /
Principles Examples Questions Outlook
Facts
• MFS is part of the SAP system environment and not a real time system
• MFS is integrated in EWM and not a separate application
• Processing of PLC requests competes with EWM user requests for system resources
• Consider note 1914127
Concern
• Will MFS be fast enough?
• Would it be possible to drive an automated warehouse from a centralized SAP System Landscape?
Remote Warehouse
Headquarter
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Will MFS be Fast Enough?
Performance: Communication channel scalability
Headquarters
SAP ERP / SAP ERP / SAP ERP / SAP ERP / SAP ERP / SAP ERP /
S/4HANA S/4HANA S/4HANA S/4HANA S/4HANA S/4HANA
PLC PLC
Local warehouse
Remote location at
Decentral EWM
same continent
on S/4HANA
PLC
PLC
Near-shore warehouse
Remote location at
other continent Decentral EWM Decentral EWM
on S/4HANA on S/4HANA
PLC PLC
Off-shore warehouse
Critical time window needs to be evaluated per warehouse Every request results in 4 messages
• Request - Acknowledgment
• Response - Acknowledgment
Additional requirements not yet implemented and probably complex or not recommended (limitation type 2)
• High sophisticated material flow throughput optimization, e.g. overall load balancing for automated equipment
• Low level PLC events to be reflected by MFS (sensor related events instead of HU related events)
• …
1
Overview
2
Functional
3
Customer
4
Frequently Asked
5
Related Topics /
Principles Examples Questions Outlook
ECC
S/4HANA
Connected
devices
RF Integration
SAP EWM Warehouse
Robotics platform automation
Hands free
picking
Communication* via Telegram or Web Services
SAP ME/MII
Pick by Voice
Augmented reality
Key Benefits
• Project-based
implementation
using SAP EWM
• Material Flow System
(MFS)
or web service calls
www.sap.com/contactsap