Title

AWS re:Invent 2023 - Resilient SAP side-by-side shop floor integration at Volkswagen (BIZ227)

Summary

• Volkswagen, through a joint venture between Capgemini and Audi called XL2, developed a use case integrating SAP ERP with shop floor systems.
• The integration aimed to ensure data accuracy and reliability for production logistics, with a focus on harmonizing material logistic processes.
• The solution was designed to be resilient, agile, and scalable, handling up to 50,000 production confirmations per day.
• The integration approach was based on three principles: keeping the core clean, caring for resilience, and reusing standards where possible.
• The solution was implemented as a side-by-side extension, leveraging AWS services and the Digital Production Platform (DPP) initiative between AWS and Volkswagen.
• The architecture included a data ingestion layer, serverless components, asynchronous communication, and a focus on data validation and monitoring.
• The integration was successful, running productively for over two years without disturbances, and is planned to be rolled out to other Volkswagen plants.

Insights

• Keeping the Core Clean: By minimizing modifications to the SAP ERP system and using cloud-based services for additional functionalities, the solution reduced technical debt and allowed for easier upgrades and innovation.
• Resilience: The system was designed for high availability and auto-scaling, with reduced coupling and robust monitoring and error handling to ensure continuous operation.
• Reusing Standards: The solution leveraged existing AWS services and standards within Volkswagen's DPP, avoiding the need to develop custom solutions from scratch.
• Side-by-Side Extension: This approach allowed for a decoupled, modular integration that could be reused across different plants, aligning with modern SAP design recommendations.
• Serverless Architecture: The use of AWS serverless services like Lambda, Kinesis, and DynamoDB provided a pay-as-you-go model, reducing costs and ensuring scalability.
• Asynchronous Communication: This design choice decoupled the SAP system from the AWS services, allowing for uninterrupted data processing even during SAP downtimes.
• Monitoring and Alerting: The solution included comprehensive monitoring and alerting mechanisms to ensure data accuracy and timely error resolution.
• Team Organization: The role of an integration manager was crucial, acting as a bridge between AWS and SAP systems and ensuring a smooth integration process.
• Future-Proofing: The integration not only solved current challenges but also set the stage for future innovations, such as AI-powered services and real-time data analysis for production planning and supply chain management.