The NLINK OPC to SAP Solution allows manufacturers to perform analysis and reporting by combining plant control and SAP business data or perform automatic measurement recording, reporting, analysis and notifications to facilitate Reliability Centered Maintenance (RCM), Condition Based Maintenance (CBM) and Operating Equipment Effectiveness (OEE). End users can define measurement points based upon control system tags, and create automatic notifications within SAP from sets of user-filtered process control alarms and events.
THE OPC to SAP PROBLEM
As a major component of predictive maintenance, condition based monitoring is essential to increasing asset longevity. Through condition based monitoring, plant managers constantly receive data that provides input about the health of their machinery. For example, by knowing the vibration behavior and temperature of certain assets, managers can make strategic decisions about preventative maintenance to avoid asset fatigue, breakdown and failure. This is especially critical in industries where failed assets potentially cost hundreds of thousands of dollars a day in lost production revenue and increased operating and maintenance costs.
Consider the simple case where pump performance data (flow, power, pressure, run hours, etc.) are measured and passed to a SCADA, DCS or Data Historian. The ability to automatically load this measurement data into the SAP PM module in order to better manage plant floor assets can provide considerable value by providing improved visibility of this measurement data and significantly increasing plant-floor operational efficiencies. This is just one example, there are literally dozens of others that are equally applicable.
THE OPC to SAP SOLUTION
For a fixed price, we deploy the NLINK OPC to SAP solution that takes your plant floor data (like pump performance data) and, after analyzing the raw data, uploads an error value (usually a statistically representative value) to SAP by creating a new SAP measurement document and/or creating a SAP Work Notification. Conditions that dictate whether or not a newly received data point will trigger the creation of a new SAP measurement document and/or SAP Work Notification are controlled by the customer.
1. Retrieve Measurement Targets from SAP
The Functional Location, Equipment and Measurement Point structure for a given Planning Plant is retrieved from SAP to make it easy to assign OPC Tags to the Measurement Points they should post readings against.
2. Post Measurement Data to SAP
Plant floor equipment Measurement Data (such as pump run-hours, etc.) are posted to the SAP PM module via Measurement Documents against existing Measurement Points on Equipment or Functional Locations on a periodic basis. The posting can be subject to:
- A Condition Threshold that must be crossed, such as a number of readings exceeding a particular value within a set amount of time.
- A Re-issue Interval that prevents posting multiple documents to SAP within a certain time period.
- An Update Interval that allows documents to gather for a length of time and then post to SAP periodically.
3. Post Work Notification Data to SAP
SAP Work Notifications can be created automatically based upon customer-defined error conditions. SAP Work Notifications are created in SAP Plant Maintenance against the Equipment that a particular Measurement Point belongs to. The posting can be subject to:
- A Re-issue Interval that prevents creating multiple Work Notifications for the same piece of equipment in SAP within a certain time period.
- An Update Interval that allows Work Notifications to gather for a length of time and then post to SAP periodically.
4. Activity Logs
The NLINK OPC to SAP Solution can generate Activity Logs summarizing the readings that cause posting to SAP, the data posted, and the results. These logs can be written to text files or the individual activity log messages can be sent via email as operator alerts.