SAP on Handheld Challenges in Implementing WM with RF Praveer Punera Varian Medical Systems, Inc. May 20, 2003

Summary Varian Medical Systems, Inc. Overview - Project Drivers - Project Highlights - Challenges - Lessons Learned

Summary Varian Medical Systems, Inc. Overview - Project Drivers - Project Highlights - Challenges - Lessons Learned

Varian Medical Systems Overview World leader in cancer therapy machines 3000 employees worldwide $873 million sales in last fiscal year Manufacturing facilities in US, UK, Switzerland and Germany

Varian Medical Systems SAP Overview 4.6C Implementation Over 1500 SAP users All major SAP modules implemented Working towards BW, CRM and SAP Portals

Summary Varian Medical Systems, Inc. Overview - Project Drivers - Project Highlights - Challenges - Lessons Learned

Project Drivers Aging hardware of legacy RF system Need for a WM system integrated real time with R/3 Inefficient warehouse activities Inaccurate transactions

Summary Varian Medical Systems, Inc. Overview - Project Drivers - Project Highlights - Challenges - Lessons Learned

Project Highlights Paperless Picking Wireless Printers Simplification of SAP transactions using middleware Production execution using RF devices 24x7 Warehouse Availability

Summary Varian Medical Systems, Inc. Overview - Project Drivers - Project Highlights - Challenges - Lessons Learned

Challenges Production Execution using RF devices Kanban and RF interface Offline processing of SAP transactions

Challenges Production Execution using RF devices Kanban and RF interface Offline processing of SAP transactions

Challenges Production Execution Using RF Devices Picking for Production Orders Paperless picking Transfer Order create from the TR Transfer Order confirmation Component issues to Production Order

Challenges Production Execution Using RF Devices Picking for Production Orders

Challenges Production Execution Using RF Devices Backflushing in Repetitive Manufacturing BOM explosion Create/Confirm Transfer Order Zero Stock check Picking from a non-WM managed storage location Backflush Tracking issues for bulk issue materials

Challenges Production Execution Using RF Devices Backflushing

Challenges Production Execution Using RF Devices Backflushing : transactional flow diagram

Challenges Production Execution Using RF Devices Function Module to Get BOM components & Stock / Bin info SAP R/3 ALE WMTOID IDOC Custom IDOC Middleware Middleware Inbound Gateway Sort components, update Backflush data table Enter Assembly - RFC Call to SAP Pick WM Item Send Transfer Order Create/ Confirm for item/ Send backflush Update data table records including non-WM, bulk Loop for next WM materials item Pick non-WM and bulk materials Update data table Loop for next non- Backflush WM material data table Backflushing

Challenges Production Execution Using RF Devices Production Orders confirmations Transfer Order and Production order information download to middleware using ALE Transfer Order confirmation Picking materials from non-WM managed storage locations Production order confirmation Tracking issues for Bulk Issue Materials

Challenges Production Execution Using RF Devices Production Orders : Transactional flow diagram

Challenges Production Execution Using RF Devices SAP R/3 ALE custom WMTOID01 IDOC with segments WMTCID01 IDOC Custom IDOC Middleware OutboundGateway Inbound Gateway Sort Components Update Production transactions Order data tables TO data Enter Production Order Operation Pick WM Item Send Transfer Order Confirm for Send Production item/Update Transaction Table Order Confirmation Records and Loop for next WM Custom Segments item Pick Non-WM Materials Update Transaction Table Loop for next Transaction non-WM item Table Production Order confirmations

Challenges Production Execution using RF devices Kanban and RF interface Offline processing of SAP transactions

Challenges Kanban and RF interface Triggering the bin status using RF device Carrying out WM activities Simplification of SAP transactions

Challenges Kanban and RF interface

Challenges Production Execution using RF devices Kanban and RF interface Offline processing of SAP transactions

Challenges Offline processing of SAP transactions Ability to run the business critical warehouse processes when SAP is down Need for a middleware solution Transactional and master data download issues Interfacing middleware with SAP Stock Overviews, Backflushing and Production Order Confirmations

Challenges Offline processing of SAP transactions Fuction Module to get BOM components BOM Tables SAP R/3 ALE Send Transfer Order Create/ Confirm for item/ Update Backflush data table Loop for next WM item Pick non-WM items, Update Backflush table Loop for next non-WM item Send Backflush Record Including Component/Free Issue and Serial Number segments WMTOID IDOC Custom Backflush data table Sort BOM Middleware File Agent components, and Replicator update BOM table Middleware Inbound Gateway BOM Table Enter Assembly , Query BOM table Off-line Validation Stock Quant table table Example : Backflushing

Summary Varian Medical Systems, Inc. Overview - Project Drivers - Project Highlights - Challenges - Lessons Learned

Lessons Learned Optimize ALE configuration Simplify Warehouse Processes Use standard SAP processes Training is the key

Q & A

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