EWM MFS

Naveen Singh- SAP EWM Specialist

Contact email: [email protected]
Key topics -MFS
• Session1
• Material Flow System
• Structure of MFS and Integration with PLC
• Q&A
• Session2
• Setting Up the Material Flow System-
• Configuration , LOSC set up
• Master Data
• Session 3 : System Demo
• Inbound Process
• Outbound Process
• Session 4:
• MFS in the Warehouse Management Monitor
• Exception Handling
• Repeating or Resending an Acknowledged Telegram
• Session 5:
• Robotics/Cobots, Monorails, High Rack Systems- ASRS, integration with SAP EWM
Material Flow System-MFS
• What is MFS ?
• The material flow system (MFS) enables you to connect an automatic
warehouse to Extended Warehouse Management(EWM)without the
need for an additional warehouse control unit.
•
EWM -MFS
EWM-MFS
• MFS is a direct communication layer within SAP EWM that seamlessly
integrates with PLCs (Programmable Logic Controllers), eliminating
the need for third-party middleware. It allows real-time data
exchange, intelligent routing, and optimized task execution for fully
automated warehouses.
• Key Benefits:
Seamless automation – Direct PLC communication for efficient
MHE ( Material Handling Equipment) operations
Optimized warehouse flow– Smart routing and workload
distribution
Cost reduction– Eliminates middleware, reducing system
complexity
Improved accuracy – Minimizes human intervention, enhancing
efficiency
Material Flow System
• Material flow system allows to connect automated warehouse to
SAP EWM via Programmable logic controllers(PLC).
• Material flow system communicates directly with the terminals
exchanging information with Automated conveyors, forklifts, ASRS
and so on, no separate warehouse control unit(WCU)is required to
communicate between SAP EWM and the automated warehouse.
Schematic diagram
Layers in Automated Warehouse
MFS is Not a Separate System But Integrated
With EWM
Structure/Components of MFS
• PLC
• COMMUNICATION CHANNEL
• COMMUNICATION POINT
• CONVEYOR SEGMENT
• RESOURCES
PLC- Structure of MFS
• PLC( Programmable logic Controller): A programmable logic
controller (PLC) or programmable controller is an
industrial computer that has been ruggedized and adapted for
the control of manufacturing processes, such as assembly lines,
machines, robotic devices, or any activity that requires high
reliability, ease of programming, and process fault diagnosis
• Structure: A typical PLC consists of a CPU, memory, input/output
(I/O) modules, and communication interfaces.
• Applications: PLCs are used in a variety of applications, from
simple machine control to complex process automation,
including manufacturing lines, robotic devices, and even
amusement park rides.
EWM-MFS
• EWM’s MFS components integrates with the PLC which in turn
controls sensors and drives.
• A PLC is a small industrial computer which consists of multiple
modules. The main purpose – at least in our context – is to
automate intralogistics processes..
EWM -MFS
• An input could for example be interpreted as being active once
a specific electrical voltage is recognized. The incoming signals
are converted to digital bits which are processed by the CPU.
• Alternatively, the PLC can receive data/data-strings in the
format of telegrams from other systems (e.g. WMS) via TCP/IP.
EWM-MFS
• The most important modules are inputs/outputs as well as the
CPU.
Input modules receive digital or analogue signals from multiple
different sources (switches, sensors, scanners, light barriers
etc.). Here an example of a case conveyor I-point with multiple
different sensors & scanners.
Communication Point -Structure of MFS
• Communication Point: A point in the ASRS at which EWM and the
PLC exchange information(such as availability status, starting or
destination point of a warehouse task or a scanner point).
• A communication point is always assigned to one PLC only.
• EWM always maps out a communication point as a storage bin
and with layout oriented storage control as a storage group.
• Each communication point belongs to certain communication
point type. For example ,Communication point Type for
Identification Point( point for storage bin assignment) or one for
scanner communication points.
Communication point- Structure of MFS
Key Properties
• Capacity
• Availability Status

• The capacity is expressed by the number of HUs permitted

simultaneously at the communication point. In this connection, the
program also takes incoming or outgoing HUs into account.
• A further important property is the availability status. You can lock a
communication point either using the PLC or via the warehouse
management monitor.
Communication channel-Structure of MFS
• COMMUNICATION CHANNEL: Connection of Messages between
MFS and a control facility (PLC)defined by IP address and a port.
• To facilitate communication between MFS and PLC , a
communication channel must be defined for a PLC.
• Several communication channels can be defined to
communicate with the same PLC. Each of these communication
channels must use a separate port.
• For example certain telegrams( Messages) are sent to a particular
port and other messages are sent to different port.
Telegram
• The communication between the
material flow system and PLCs is
facilitated through telegram
communication.
• Messages of communication channel
are communicated sequentially.
• This means the system does not send
message 2 until the acknowledgement
of receipt has been received for
message1.

One communication channel per control is

sufficient
Communication channel-Structure of MFS
• Example: MFS is to communicate with the three stacker cranes in your
warehouse via a separate channel for each one. With regard to the
prestorage area, you expect a higher incidence of telegrams. You therefore
define 2 channels (port 1 and port 2) for the responsible PLC. All HU-
related telegrams are passed along channel 1, whereas channel 2 is for all
status telegrams (malfunction reports for communication points and
segments). You therefore agree with the person responsible for the PLC
that status telegrams are to be transmitted via port 2. In EWM, you specify
that telegram type STAR (status request from EWM to MFS) is to be routed
via channel 2.
• Stacker cranes are automated machines used in warehouses to store
and retrieve pallets or boxes. They move in three dimensions:
lengthwise along the aisle, vertically to reach different heights, and
depth-wise to place or pick up items from racking structures
Conveyor segment- Structure of MFS
• Conveyor segments : Leg between two communication points
• Conveyor segments physically transport handling units (HUs) from one
communication point to the next.
• Assign conveyor segments to your start and end points in layout-oriented
storage control.
• Combine different conveyor segments to form a conveyor segment group
by conveyor segment group type (such as status).
• for example, you can assign an exception to the entire conveyor segment
group instead of to individual conveyor segments in the case of a
malfunction report; the system then holds back orders for these conveyor
segments
EWM-MFS→ PLC Communication
Key point
EWM –MFS- Practical examples
Pallet/HU moves from one conveyor segment to another conveyor segment >
PLC receives input signals from the sensor(s) once the HU has left/arrived at
a segment

Create a stock removal task for a crane to remove a pallet from a bin
in the given rack > start the motor to move the crane to the source
position
Overview of Communication from EWM to PLC
 Communication Point –Structure of MFS
Example
1. A conveyor system moves a HU to a scanner ( This is defined as communication Point –CP01 of type
Identification type in the MFS )
2. A PLC sends the data read by the scanner ( HU Number) to EWM together with the name of
communication point.
3. EWM triggers the action( search for storage bin) defined for this telegram type (scanner telegram) and
this communication point type(identification point).
4. EWM determines the next interim destination on the way to the final storage bin and sends an
appropriate telegram to the PLC ( transport HU to the next communication point CP02).
5. The PLC causes the HU to be transported to the next interim communication point via the conveyor
system.
6. When the HU arrives at CP02, the PLC sends a new telegram (Logon at CP02),this communication
point is set with the type simple communication point . In case of logons at simple communication
point, a function module is defined that reposts the HU at the new point and determines the next
destination on the way to the final bin
Flow Diagram
Storage type Communication Communication PLC Telegram
Point Point type
CP01 Scanner

CP02 Simple
communication

Conveyor system
EWM -MFS Telegram :HU Number and
Communication Point HU
Based on the PLC
inputs, EWM
determines the next Scanner- CP01
interim bin Telegram: Transport HU

Based on the PLC

telegram ,a Function
module in EWM Telegram: Logon to CP02
reposts the HU at Next interim point- CP02
the CP02 and next
bin is determined Telegram: Transport HU

Final storage bin

Flow Diagram
Storage type Communication Communication PLC Telegram
Point Point type
CP01 Scanner

CP02 Simple
communication

Conveyor system
EWM -MFS Telegram :HU Number and
Communication Point HU
Based on the PLC
inputs, EWM
determines the next Scanner- CP01
interim bin Telegram: Transport HU

Based on the PLC

telegram ,a Function
module in EWM Telegram: Logon to CP02
reposts the HU at Next interim point- CP02
the CP02 and next
bin is determined Telegram: Transport HU

Final storage bin

Basic Setup of MFS
LOSC in MFS
• Basic Overview of LOSC
LOSC Processing Steps
LOSC Processing Steps
LOSC Customizing setup- Highlevel
Function Modules in MFS process
• /SCWM/MFS_WT_DET
• The FM is directly called in the context of posting the WT creation
and WT confirmation to database.