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

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

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

4. 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

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

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

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

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

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

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

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

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

13. 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

14. Challenges Production Execution Using RF Devices
Picking for Production Orders

15. 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

16. Challenges Production Execution Using RF Devices
Backflushing

17. Challenges Production Execution Using RF Devices
Backflushing : transactional flow diagram

18. 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

19. 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

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

21. 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

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

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

24. Challenges Kanban and RF interface

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

26. 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

27. 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

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

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

30. Q & A

31. Thank you for attending!
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Session Code: 4908