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Manufacturing Execution Systems (MES) Why MES ? Anand Subramaniam
Highlights ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Terms - ERP, MES & CIM ,[object Object],[object Object],[object Object]
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
Business Systems
Computer Integrated Manufacturing
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 ,
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
Why MES? ,[object Object],[object Object],[object Object]
Business Drivers ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Benefits ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
MES Components ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
ISA 95 ,[object Object],[object Object],[object Object],[object Object],[object Object]
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
MES Functionality ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
MES Functionality (Contd.) ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
MES Functionality (Contd.) ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
MES Functionality (Contd.) ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
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)
MES - Vendors ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
[object Object],[object Object]

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Manufacturing Execution System

  • 1. Manufacturing Execution Systems (MES) Why MES ? Anand Subramaniam
  • 2.
  • 3.
  • 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
  • 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. 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.
  • 10.
  • 11.
  • 12.
  • 13.
  • 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.
  • 16.
  • 17.
  • 18.
  • 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.
  • 21.