INELDS Indoor & Outdoor Products factory in Nashik has taken a major step towards the factory digitalization. After the successful implementation of several short term digitalization projects like E-Gemba, E-gallery and many more, the factory has now created a new benchmark by integrating Integrated Traceability System (ITS) with SAP ERP. This is the first kind of implementation within ABB India for external software integrating the end to end manufacturing process software tools. The factory has started journey to implement the digital solution in manufacturing process and moving towards the talk of the town concept of smart factories.
Old Data flow among the tools.
Integrated Traceability System (ITS) provides end to end traceability of the components, process and products during the manufacturing process.
The existing system involves following process.
- Data updating in SAP
- The user used to book the sale order along with the configuration of the breaker in SAP. Also used to generate production orders.
- Data update in the master plan
- The user then feeds the entire production data in an excel sheet.
- Data uploading on Integrated traceability system
- The user then used to upload the data on the server of the ITS system.
- The data would act as a major contributor to accuracy for the entire system
- Uploading RTC’s on server
- Once the breaker has been manufactured, RTC’s were uploaded on the server by the user.
Seamless data flow after Integration
- Data updating in SAP
- The user used to book the sale order along with the configuration of the breaker in SAP.
Automatic data uploading on Integrated traceability systemSAP triggers following information to ITS
- Configuration data
- Production Order data
- Customer details
- Special points
ITS then acts as a master and send out RTC’s automatically
- The system then sends out the details of the manufactured breaker on the server.
SAP sales order configuration will trigger the production order, the details in production order and sales order will be transferred to ITS for respective order with define frequency. These details will be available on the screen on each production stations with respective information required to those stations.
Benefits of integration - Integrate SAP with ITS
Waste Elimination
- Helping to environment by reducing the entries on paper registers or forms.
- Manhours required to upload of Excel plan to ITS is saved.
- Accurate inputs will reduce the production loss.
- Online monitoring of the process.
Process Improvement
- Integration of SAP and ITS will improve quality of inputs to ITS and e-Gemba.
- Integration of ITS with SAP will eliminate manual intervention.
Data: Realtime, Accurate and automated
- Real time data in ITS from SAP.
- Seamless information flow from SAP to the ITS
- Additional reports will be developed in ITS after getting data from SAP as per users requirement.
The above initiatives accelerated the smart factory journey of Indoor & Outdoor products.
We are planning for the horizontal deployment of the same over other product range.
