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Manufacturing Execution Systems (MES) Why MES ? Anand Subramaniam
Highlights <ul><li>Terms & Conceptual Overview </li></ul><ul><li>Relationship & Data Flow - ERP, MES & CIM </li></ul><ul><...
Terms - ERP, MES & CIM <ul><li>ERP systems handle financial functions, customer orders and send production requests to the...
Conceptual Overview Relationship Management Enterprise Resource Planning Manufacturing Execution Systems Process Control A...
Business Systems
Computer Integrated Manufacturing
Relationship - ERP & MES Corporate Plant MRP II/ ERP MES PLC Robots/ AGV DCS Planning  When/What to make  Planned/standa...
Data Flow – ERP & MES MESA International-White Paper MPRII/ERP Forecasting Costing Production Planning Product Definition ...
Why MES? <ul><li>MES have evolved to fill the communication gap between the manufacturing planning system (MRP, ERP, etc.)...
Business Drivers <ul><li>Standard processes to enable benchmarking and best practices </li></ul><ul><li>Seamless Integrati...
Benefits <ul><li>Increases Operational Excellence </li></ul><ul><li>Improves Asset Utilisation and the Management of Asset...
MES Components <ul><li>Core </li></ul><ul><ul><li>Material and Production Tracking  </li></ul></ul><ul><ul><li>Material Ha...
ISA 95 <ul><li>ISA =  I nstrumentation,  S ystems, and  A utomation Society ( ISA ) Standard </li></ul><ul><li>Standard th...
Business Functions Demand Planning Supply Chain Planning Production Planning Cost Accounting Warehouse Management Maintena...
MES Functionality <ul><li>Dispatching and Production </li></ul><ul><ul><li>Manages the flow of production in the form of j...
MES Functionality (Contd.) <ul><li>Process Management </li></ul><ul><ul><li>Monitors production and either automatically c...
MES Functionality (Contd.) <ul><li>Performance Analysis </li></ul><ul><ul><li>Provides real-time reporting of actual manuf...
MES Functionality (Contd.) <ul><li>Labour Management  </li></ul><ul><ul><li>Provides status of personnel.  </li></ul></ul>...
System / Response Time Planning Level Execution Level Control Level Supervisory Level ms  seconds  hours  days  weeks  mon...
MES - Vendors <ul><li>ABB Automation Technology Products (www.abb.com)  </li></ul><ul><li>GE Fanuc Automation (www.gefanuc...
<ul><li>Good Luck </li></ul><ul><li>http://www.linkedin.com/in/anandsubramaniam   </li></ul>
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Manufacturing Execution System

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Transcript of "Manufacturing Execution System"

  1. 1. Manufacturing Execution Systems (MES) Why MES ? Anand Subramaniam
  2. 2. Highlights <ul><li>Terms & Conceptual Overview </li></ul><ul><li>Relationship & Data Flow - ERP, MES & CIM </li></ul><ul><li>Why MES? </li></ul><ul><li>Business Drivers / Benefits </li></ul><ul><li>MES Components </li></ul><ul><li>ISA 95 </li></ul><ul><li>MES – High Level Functionality </li></ul><ul><li>System / Response Time </li></ul><ul><li>MES Vendors </li></ul>
  3. 3. Terms - ERP, MES & CIM <ul><li>ERP systems handle financial functions, customer orders and send production requests to the factory floor. </li></ul><ul><li>MES provide overall control and management of the factory floor, and provide updated information to ERP systems. </li></ul><ul><li>The simplest model of CIM has MES as the middle ground between ERP systems and individual machine and automation controls </li></ul>
  4. 4. Conceptual Overview Relationship Management Enterprise Resource Planning Manufacturing Execution Systems Process Control Asset Optimisation Customer / Vendor / Employee Production Planning & Scheduling Robotics Motors & Drives Sensors & Meters Power Electronics Enterprise Management Factory Management Automation and Control Process Measurement, Actuation, Energy Distribution Enterprise Asset Management Real-Time Systems Transaction Systems Transformers Switchgear
  5. 5. Business Systems
  6. 6. Computer Integrated Manufacturing
  7. 7. Relationship - ERP & MES Corporate Plant MRP II/ ERP MES PLC Robots/ AGV DCS Planning  When/What to make  Planned/standard lead times/ yields/wastes/costs Execution  Production management/tracking - WIP, equipment, operators  Production scheduling  Quality control/SQC  Costing  Maintenance  Management functions - Communications, reporting Control  Ladder logic  Continuous feedback  PID  Advanced control actual process conditons completion of process steps and operations, performance of equipment and raw material & operator actions production planning, scheduling recipes process setpoints operating instructions reporting or batch, production run completion ,
  8. 8. Data Flow – ERP & MES MESA International-White Paper MPRII/ERP Forecasting Costing Production Planning Product Definition Process Definition SOP Human Resources Inventory Management Purchasing Distribution MES Resource Alloc./Status Operations Scheduling Production Dispatching Document Control Data Collection/Acq. Labor Management WIP Status/Traceability Quality Management Performance Analysis Process Management Product Tracking and Genealogy Maintenance Management Monitoring & Sensing Process Equipment Environment Labor Material Control Machine Control Regulatory Control Realtime QC Advanced Process Controls Operations Process Sequencing Machine & Process Instructions Labor Instructions Human Machine Interfacing Safety Maintenance Focus: Customer Decision Location: Office Focus: Product Decision Location: Factory Focus: Process Decision Location: Shop Floor/Plant Floor Planning Execution Control Order Status/COmpletions /Start-Due-End Resource Status/Usage Labor Status/Usage Material Status/Usage Actual BOM/Formula/Recipe/ Drawing/Part Program Actual Routing/Process Product Genealogy/Traceability /As Built Information Scrap/Waste Product Demand BOM/Formula/Recipe/Drawing /Part Program Resources Routing/Process Labor Characteristics Inventory Status SOP, HEALTH, WORK Instructions Process Instructions: Recipes, Work Instructions, Part Programs, Order Specific, Machine Utilisation, Work Certification Requirements Operator Instructions: Scheduled (predictive) & Preventative Maintenance, Material Safety Instructions (documents), Machine Operation Instructions (documents) Drill Down (inquiries) Status Process Status Batch End Reports Ad Hoc Inquires Materials Analysis Events: Time/Date/Lot/Alarms Data Collected from Monitoring Functions: Process, Equipment, Environment, Labor, Material, Product Parameters
  9. 9. Why MES? <ul><li>MES have evolved to fill the communication gap between the manufacturing planning system (MRP, ERP, etc.) and the control systems to run equipment on the plant floor. </li></ul><ul><li>Co-ordinate functions on the shop floor to optimise the plant activities </li></ul><ul><li>Provide visibility and flexibility to effectively manage supply chain </li></ul>
  10. 10. Business Drivers <ul><li>Standard processes to enable benchmarking and best practices </li></ul><ul><li>Seamless Integration </li></ul><ul><li>Resource Utilisation </li></ul><ul><li>Consistent Documentation </li></ul><ul><li>Visibility of data globally </li></ul><ul><li>Accurate and consistent measurement and reporting </li></ul>
  11. 11. Benefits <ul><li>Increases Operational Excellence </li></ul><ul><li>Improves Asset Utilisation and the Management of Assets </li></ul><ul><li>Benefits as listed by Manufacturing Enterprise Solutions Association ( http:// www.mesa.org ) </li></ul><ul><ul><li>Reduces manufacturing cycle time </li></ul></ul><ul><ul><li>Reduces or eliminated data </li></ul></ul><ul><ul><li>Reduces work-in-process </li></ul></ul><ul><ul><li>Reduces or eliminated paperwork between shifts </li></ul></ul><ul><ul><li>Reduces lead times </li></ul></ul><ul><ul><li>Improves product quality </li></ul></ul><ul><ul><li>Eliminated lost paperwork </li></ul></ul><ul><ul><li>Empowers plant operations people </li></ul></ul>
  12. 12. MES Components <ul><li>Core </li></ul><ul><ul><li>Material and Production Tracking </li></ul></ul><ul><ul><li>Material Handling and Production Procedures </li></ul></ul><ul><ul><li>Resource management and allocation </li></ul></ul><ul><ul><li>Production Dispatching </li></ul></ul><ul><ul><li>Data Collection </li></ul></ul><ul><li>Extensions </li></ul><ul><ul><li>Compliance </li></ul></ul><ul><ul><li>Quality Assurance </li></ul></ul><ul><ul><li>Performance Analysis </li></ul></ul><ul><ul><li>Detail Scheduling </li></ul></ul><ul><ul><li>Document Management </li></ul></ul><ul><ul><li>Labor Management </li></ul></ul>
  13. 13. ISA 95 <ul><li>ISA = I nstrumentation, S ystems, and A utomation Society ( ISA ) Standard </li></ul><ul><li>Standard that defines how to link Enterprise systems with MES layer. </li></ul><ul><ul><li>The MES Functionality </li></ul></ul><ul><ul><li>The Data base schema at the MES Level </li></ul></ul><ul><ul><li>The Messages between the Enterprise system and MES </li></ul></ul>
  14. 14. Business Functions Demand Planning Supply Chain Planning Production Planning Cost Accounting Warehouse Management Maintenance Management Material Management Human Resource Management Sales & Distribution Enterprise Performance Reporting Level 4 Business Planning & Logistics Level 2 Plant Floor Control Manufacturing Execution Systems SCADA / PCS Systems Detail Scheduling Performance Management Process Analysis Recipe Management Process Optimisation Production History WIP Material Management Resource Management Production Execution Quality Management Level 3 Manufacturing Operations Real-Time Monitoring Real-Time Execution Real-Time SPC Real-Time Control
  15. 15. MES Functionality <ul><li>Dispatching and Production </li></ul><ul><ul><li>Manages the flow of production in the form of jobs, orders, batches, lots and work orders by dispatching production to specific equipment and personnel. </li></ul></ul><ul><ul><li>Includes information that is presented in the sequence in which the work needs to be done. </li></ul></ul><ul><li>Quality Management </li></ul><ul><ul><li>Provides real-time measurements collected form manufacturing to assure proper product quality control and to identify problems requiring attention. </li></ul></ul><ul><ul><li>Includes SPC / SQC tracking and management of offline inspection operations </li></ul></ul><ul><li>Data Collection & Acquisition </li></ul><ul><ul><li>Obtains operational production and parametric data associated with production equipment and processes. </li></ul></ul><ul><ul><li>Provides real-time statuses of production equipment and processes </li></ul></ul>
  16. 16. MES Functionality (Contd.) <ul><li>Process Management </li></ul><ul><ul><li>Monitors production and either automatically corrects or provides decision support to operators for correcting and improving in-process functions. It may include alarm management to handle process deviations </li></ul></ul><ul><li>Production Tracking & Genealogy </li></ul><ul><ul><li>Provides status of production and disposition of work. </li></ul></ul><ul><ul><li>Status information may include personnel, materials used, current production conditions. Includes recording of production information to allow forward and backward traceability. </li></ul></ul><ul><li>Document Control </li></ul><ul><ul><li>Control records and forms that must be maintained with the production unit. </li></ul></ul><ul><ul><li>Includes work instructions, recipes, drawings, standard operating procedures (SOP), batch records, shift to shift communication. </li></ul></ul><ul><ul><li>It sends instructions down to operations and device controls </li></ul></ul>
  17. 17. MES Functionality (Contd.) <ul><li>Performance Analysis </li></ul><ul><ul><li>Provides real-time reporting of actual manufacturing operations results along with comparisons to past history and expected results. </li></ul></ul><ul><ul><li>Performance results include resource utilisation, resource availability, cycle time, conformance to schedule and standards. </li></ul></ul><ul><ul><li>May include SPC / SQC analysis </li></ul></ul><ul><li>Operational Detail Scheduling </li></ul><ul><ul><li>Provides sequencing based on priorities, attributes, characteristics and production rules. </li></ul></ul><ul><ul><li>It is finite and it recognises alternative and overlapping operations to calculate timing of equipment loading </li></ul></ul><ul><li>Resource Allocation & Status </li></ul><ul><ul><li>Manage the resources directly associated with control and manufacturing. </li></ul></ul>
  18. 18. MES Functionality (Contd.) <ul><li>Labour Management </li></ul><ul><ul><li>Provides status of personnel. </li></ul></ul><ul><ul><li>Includes time and attendance, certification tracking, as well as preparation work as basis for activity–based costing. </li></ul></ul><ul><ul><li>May interact with resource allocation for optimal assignments. </li></ul></ul><ul><li>Maintenance Management </li></ul><ul><ul><li>Functionality for maintaining equipment and tools. </li></ul></ul><ul><ul><li>Ensures equipment and tools availability for manufacturing. </li></ul></ul><ul><ul><li>May also include scheduling for periodic or preventive maintenance. </li></ul></ul><ul><ul><li>Maintains history of past events to aid in diagnosing problems. </li></ul></ul>
  19. 19. System / Response Time Planning Level Execution Level Control Level Supervisory Level ms seconds hours days weeks month years ERP (Enterprise Resource Planning) DCS (Distributed Control System) MES (Manufacturing Execution System) PLC (Programmable Logic Controller) SCADA (Supervisory Control and Data Acquisition)
  20. 20. MES - Vendors <ul><li>ABB Automation Technology Products (www.abb.com) </li></ul><ul><li>GE Fanuc Automation (www.gefanuc.com) </li></ul><ul><li>Honeywell Hi-Spec Solutions (www.hispec.com) </li></ul><ul><li>Kronos Inc ( www.kronos.com ) </li></ul><ul><li>RockwellSoftware (www.software.rockwell.com) </li></ul><ul><li>Schneider Electric (/www.schneider-electric.com) </li></ul><ul><li>Siemens Energy & Automation ( www.sea.siemens.com ) </li></ul><ul><li>Tecnomatix Tecnologies (www.tecnomatix.com) </li></ul>
  21. 21. <ul><li>Good Luck </li></ul><ul><li>http://www.linkedin.com/in/anandsubramaniam </li></ul>
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