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Green Manufacturing: an Inconvenient Reality

Applies to:
SAP MII (Manufacturing Integration and Intelligence)

Summary
This article provides an overview of growing importance associated with Green Manufacturing and how SAP MII capabilities can be leveraged to combine data from different data sources and slice and dice this information for effective analysis Author: Arijeet Majumdar and AN Navaneeth

Company: SAP Created on: 16 December 2008

Author Bio
Arijeet Majumdar and AN Navaneeth work in Solution Management Manufacturing at SAP with a focus on SAP MII.

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Green Manufacturing: An Inconvenient Reality

Table of Contents
Introduction .........................................................................................................................................................3 Green Manufacturing: An Inconvenient Reality ..............................................................................................3 How SAP MII can be used to create a Green Manufacturing Application Dashboard .......................................4 Copyright.............................................................................................................................................................7

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Green Manufacturing: An Inconvenient Reality

Introduction
Green Manufacturing: An Inconvenient Reality Are you turning green at the thought of going green? Like it or not more environmental regulations are on the way, and manufacturers who don't jump on the green bandwagon may be left behind Jonathan Katz, Industry Week, May 01 2007 We all know manufacturing is all about taking raw materials, which are separate materials of a finished product, and putting the materials together to form a finished product. In today's economy many businesses and people alike are concerned about our environment considering the fact that global warming and subsequent climate change is most talked topic these days. More and more people and businesses are recycling certain things to help save the environment, but when you think about manufacturing you don't really see any way that it can be done and still help the environment; this is where green manufacturing comes in. Green manufacturing is all about choices in manufacturing methods that support and sustain a renewable way of producing products and/or services that will not harm you or the environment. In our current economy manufacturing is one of the biggest sources of pollution and wasted energy. In fact manufacturing accounts for about 25% of the energy used each year in industrial countries. But aside from all of the energy it consumes manufacturing often leads to pollution because most of the energy that is used in manufacturing is obtained via combustion processes from coal, coke, natural gases, oil, and waste which generate a lot of harmful greenhouse gases. No matter which kind of manufacturing you are doing it is going to create some type of pollution because of the amount and type of waste that is produced. If your company is producing electronic items you are going to have problems disposing of certain components because of the various depositions and etching technologies that are being used in making the components, the same holds true with chemical and primary material plants. Regardless of what industry you are working is waste disposal and energy consumption is a major problem. But that is where green manufacturing comes in, by making a few small changes you can help make your manufacturing plant more environmentally friendly and soften the regulatory/compliance blow. Green Manufacturing is all about: 1. Using process improvements to maximize the yield and to help minimize the waste that is produced 2. Control of hazardous material use in any of the products that might end up in waste systems (landfills) or in the environment 3. Providing a cleaner source of energy through new technology 4. Decreasing energy consumption in process by using new technology 5. Converting pollutants and wastes into byproducts and promote their use and recycling along with the use of the product. 6. Finally making the process much better for the environment and better use of the materials that are being used. Green Manufacturing application is methodical way of identifying and addressing companys environmental concerns. It ensures compliance and allows for continuous improvement. It requires upper level management support and makes environmental compliance a priority. It also goes beyond compliance framework for communication, efficiency, and potential profitability. Also part of the beat-them-to-the-punch approach includes embracing green technology as a marketing advantage. Manufacturing giants General Electric, DuPont and Toyota have been at the forefront of selling green. In doing so, many of these companies also work with the government to help develop policy. For instance, earlier in the year a group of manufacturers and big business, which includes GE and DuPont, formed an organization that calls for a cap on carbon dioxide emissions. In short Green Manufacturing is Green Manufacturing seamlessly identifies, manages and controls the flow of environmental waste and efficient use of raw materials, energy and water with a goal of minimizing impact on environment and related environmental costs

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Green Manufacturing: An Inconvenient Reality

How SAP MII can be used to create a Green Manufacturing Application Dashboard
Present Gaps: For Head, Operations of an industrial plant would like to monitor his operational performance viz., green and he finds that the various information is residing disparate systems (SAP systems, non SAP systems, local databases etc). He will find the entire process cumbersome to effectively monitor his plants operational performance. For example he would like to use the reports on waste generation and disposal, hazardous material use, work hygiene monitoring from EHS module in SAP ERP; energy consumption details from SCADA systems installed in plant; emissions data, water use and monitoring of environmental management system objectives status details from local databases; production details, material use, yield etc from SAP ERP system. The challenge here is he would not be able to effectively monitor the above major KPIs above which have direct impact towards making the process much better for the environment. Green Manufacturing Dashboard SAP MII has unique capabilities to combine data from different data sources. With its connector framework SAP MII can extract data from disparate systems at the aggregation level needed form the origin of that data thereby increasing data quality compared to holding it in multiple stages in execution. If data cleansing is needed, SAP MII can provide business logic templates to perform this process automatically. SAP MII connector framework will allow Head, Operations to better understand how well a manufacturing area is performing on green performance and to identify what is limiting higher effectiveness. SAP MIIs capability to handle data on different levels of aggregation like resource/line up to plant or multi sites will help in the slice and dice of information for effective analysis. SAP MII can provide the capabilities to help answer the following questions: 1. 2. 3. 4. 5. 6. 7. How effectively materials are processed How much yield is being produced How are the emissions trend How much of water is being consumed Energy consumption details How much of waste is being generated What is current measure of converting pollutants and wastes into byproducts and promote their use and recycling along with the use of the product 8. Work hygiene monitoring of the plant 9. Hazardous material use details

Apart from the above it could also be built to address 1. Alerts if any key KPI deviates from plan 2. Task assignment for effective decision making 3. Generation of various Environmental Performance reports to Top Management and Compliance Manager on plant performance viz., Green KPIs

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Green Manufacturing: An Inconvenient Reality

Sample MII Dashboard to support Green Manufacturing:

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Green Manufacturing: An Inconvenient Reality

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Green Manufacturing: An Inconvenient Reality

Copyright
2009 SAP AG. All rights reserved. No part of this publication may be reproduced or transmitted in any form or for any purpose without the express permission of SAP AG. The information contained herein may be changed without prior notice. Some software products marketed by SAP AG and its distributors contain proprietary software components of other software vendors. Microsoft, Windows, Outlook, and PowerPoint are registered trademarks of Microsoft Corporation. IBM, DB2, DB2 Universal Database, OS/2, Parallel Sysplex, MVS/ESA, AIX, S/390, AS/400, OS/390, OS/400, iSeries, pSeries, xSeries, zSeries, System i, System i5, System p, System p5, System x, System z, System z9, z/OS, AFP, Intelligent Miner, WebSphere, Netfinity, Tivoli, Informix, i5/OS, POWER, POWER5, POWER5+, OpenPower and PowerPC are trademarks or registered trademarks of IBM Corporation. Adobe, the Adobe logo, Acrobat, PostScript, and Reader are either trademarks or registered trademarks of Adobe Systems Incorporated in the United States and/or other countries. Oracle is a registered trademark of Oracle Corporation. UNIX, X/Open, OSF/1, and Motif are registered trademarks of the Open Group. Citrix, ICA, Program Neighborhood, MetaFrame, WinFrame, VideoFrame, and MultiWin are trademarks or registered trademarks of Citrix Systems, Inc. HTML, XML, XHTML and W3C are trademarks or registered trademarks of W3C, World Wide Web Consortium, Massachusetts Institute of Technology. Java is a registered trademark of Sun Microsystems, Inc. JavaScript is a registered trademark of Sun Microsystems, Inc., used under license for technology invented and implemented by Netscape. MaxDB is a trademark of MySQL AB, Sweden. SAP, R/3, mySAP, mySAP.com, xApps, xApp, SAP NetWeaver, and other SAP products and services mentioned herein as well as their respective logos are trademarks or registered trademarks of SAP AG in Germany and in several other countries all over the world. All other product and service names mentioned are the trademarks of their respective companies. Data contained in this document serves informational purposes only. National product specifications may vary. These materials are subject to change without notice. These materials are provided by SAP AG and its affiliated companies ("SAP Group") for informational purposes only, without representation or warranty of any kind, and SAP Group shall not be liable for errors or omissions with respect to the materials. The only warranties for SAP Group products and services are those that are set forth in the express warranty statements accompanying such products and services, if any. Nothing herein should be construed as constituting an additional warranty. These materials are provided as is without a warranty of any kind, either express or implied, including but not limited to, the implied warranties of merchantability, fitness for a particular purpose, or non-infringement. SAP shall not be liable for damages of any kind including without limitation direct, special, indirect, or consequential damages that may result from the use of these materials. SAP does not warrant the accuracy or completeness of the information, text, graphics, links or other items contained within these materials. SAP has no control over the information that you may access through the use of hot links contained in these materials and does not endorse your use of third party web pages nor provide any warranty whatsoever relating to third party web pages. Any software coding and/or code lines/strings (Code) included in this documentation are only examples and are not intended to be used in a productive system environment. The Code is only intended better explain and visualize the syntax and phrasing rules of certain coding. SAP does not warrant the correctness and completeness of the Code given herein, and SAP shall not be liable for errors or damages caused by the usage of the Code, except if such damages were caused by SAP intentionally or grossly negligent.

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