The document discusses manufacturing execution systems (MES) and their relationship to ERP systems and control systems. MES provide control and management of the factory floor and updated information to ERP systems. They have evolved to fill communication gaps and coordinate functions on the shop floor. MES provide benefits like increased operational excellence, improved asset utilization, reduced cycle times and lead times, improved quality, and empowered plant operations staff. Key components of MES include material and production tracking, resource management, and data collection.

1. 11
Manufacturing ExecutionManufacturing Execution
Systems (MES)Systems (MES)
Why MES ?Why MES ?
Anand SubramaniamAnand Subramaniam

2. 22
HighlightsHighlights
Terms & Conceptual OverviewTerms & Conceptual Overview
Relationship & Data Flow - ERP, MES & CIMRelationship & Data Flow - ERP, MES & CIM
Why MES?Why MES?
Business Drivers / BenefitsBusiness Drivers / Benefits
MES ComponentsMES Components
ISA 95ISA 95
MES – High Level FunctionalityMES – High Level Functionality
System / Response TimeSystem / Response Time
MES VendorsMES Vendors

3. 33
Terms - ERP, MES & CIMTerms - ERP, MES & CIM
ERP systems handle financial functions, customerERP systems handle financial functions, customer
orders and send production requests to theorders and send production requests to the
factory floor.factory floor.
MES provide overall control and management ofMES provide overall control and management of
the factory floor, and provide updatedthe factory floor, and provide updated
information to ERP systems.information to ERP systems.
The simplest model of CIM has MES as the middleThe simplest model of CIM has MES as the middle
ground between ERP systems and individualground between ERP systems and individual
machine and automation controlsmachine and automation controls

4. 44
Conceptual OverviewConceptual 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. 55
Business SystemsBusiness Systems

6. 66
Computer Integrated ManufacturingComputer Integrated Manufacturing

7. 77
Relationship - ERP & MESRelationship - ERP & MES
Corporate
Plant
MRP II/
ERP
MES
PLC
Robots/
AGV
DCS
production planning,
scheduling
recipes
process setpoints
operating instructions
reporting or
batch,
production run
completion
,
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

8. 88
Data Flow – ERP & MESData 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
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
Focus:
Customer
Decision Location:
Office
Focus:
Product
Decision Location:
Factory
Focus:
Process
Decision Location:
Shop Floor/Plant Floor
Planning Execution Control

9. 99
Why MES?Why MES?
MES have evolved to fill theMES have evolved to fill the
communication gap between thecommunication gap between the
manufacturing planning system (MRP,manufacturing planning system (MRP,
ERP, etc.) and the control systems to runERP, etc.) and the control systems to run
equipment on the plant floor.equipment on the plant floor.
Co-ordinate functions on the shop floorCo-ordinate functions on the shop floor
to optimise the plant activitiesto optimise the plant activities
Provide visibility and flexibility toProvide visibility and flexibility to
effectively manage supply chaineffectively manage supply chain

10. 1010
Business DriversBusiness Drivers
Standard processes to enableStandard processes to enable
benchmarking and best practicesbenchmarking and best practices
Seamless IntegrationSeamless Integration
Resource UtilisationResource Utilisation
Consistent DocumentationConsistent Documentation
Visibility of data globallyVisibility of data globally
Accurate and consistent measurementAccurate and consistent measurement
and reportingand reporting

11. 1111
BenefitsBenefits
Increases Operational ExcellenceIncreases Operational Excellence
Improves Asset Utilisation and the Management ofImproves Asset Utilisation and the Management of
AssetsAssets
Benefits as listed by Manufacturing EnterpriseBenefits as listed by Manufacturing Enterprise
Solutions Association (Solutions Association (http://http://www.mesa.orgwww.mesa.org))
– Reduces manufacturing cycle timeReduces manufacturing cycle time
– Reduces or eliminated dataReduces or eliminated data
– Reduces work-in-processReduces work-in-process
– Reduces or eliminated paperwork between shiftsReduces or eliminated paperwork between shifts
– Reduces lead timesReduces lead times
– Improves product qualityImproves product quality
– Eliminated lost paperworkEliminated lost paperwork
– Empowers plant operations peopleEmpowers plant operations people

12. 1212
MES ComponentsMES Components
CoreCore
– Material and Production TrackingMaterial and Production Tracking
– Material Handling and Production ProceduresMaterial Handling and Production Procedures
– Resource management and allocationResource management and allocation
– Production DispatchingProduction Dispatching
– Data CollectionData Collection
ExtensionsExtensions
– ComplianceCompliance
– Quality AssuranceQuality Assurance
– Performance AnalysisPerformance Analysis
– Detail SchedulingDetail Scheduling
– Document ManagementDocument Management
– Labor ManagementLabor Management

13. 1313
ISA 95ISA 95
ISA =ISA = IInstrumentation,nstrumentation, SSystems, andystems, and
AAutomation Society (utomation Society (ISAISA) Standard) Standard
Standard that defines how to linkStandard that defines how to link
Enterprise systems with MES layer.Enterprise systems with MES layer.
– The MES FunctionalityThe MES Functionality
– The Data base schema at the MES LevelThe Data base schema at the MES Level
– The Messages between the Enterprise systemThe Messages between the Enterprise system
and MESand MES

14. 1414
Business FunctionsBusiness 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
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
Level 2
Plant Floor
Control
Manufacturing Execution Systems
SCADA / PCS Systems

15. 1515
MES FunctionalityMES Functionality
Dispatching and ProductionDispatching and Production
– Manages the flow of production in the form of jobs, orders,Manages the flow of production in the form of jobs, orders,
batches, lots and work orders by dispatching production tobatches, lots and work orders by dispatching production to
specific equipment and personnel.specific equipment and personnel.
– Includes information that is presented in the sequence in whichIncludes information that is presented in the sequence in which
the work needs to be done.the work needs to be done.
Quality ManagementQuality Management
– Provides real-time measurements collected form manufacturingProvides real-time measurements collected form manufacturing
to assure proper product quality control and to identify problemsto assure proper product quality control and to identify problems
requiring attention.requiring attention.
– Includes SPC / SQC tracking and management of offlineIncludes SPC / SQC tracking and management of offline
inspection operationsinspection operations
Data Collection & AcquisitionData Collection & Acquisition
– Obtains operational production and parametric data associatedObtains operational production and parametric data associated
with production equipment and processes.with production equipment and processes.
– Provides real-time statuses of production equipment andProvides real-time statuses of production equipment and
processesprocesses

16. 1616
MES Functionality (Contd.)MES Functionality (Contd.)
Process ManagementProcess Management
– Monitors production and either automatically corrects or providesMonitors production and either automatically corrects or provides
decision support to operators for correcting and improving in-decision support to operators for correcting and improving in-
process functions. It may include alarm management to handleprocess functions. It may include alarm management to handle
process deviationsprocess deviations
Production Tracking &Production Tracking & GenealogyGenealogy
– Provides status of production and disposition of work.Provides status of production and disposition of work.
– Status information may include personnel, materials used,Status information may include personnel, materials used,
current production conditions. Includes recording of productioncurrent production conditions. Includes recording of production
information to allow forward and backward traceability.information to allow forward and backward traceability.
Document ControlDocument Control
– Control records and forms that must be maintained with theControl records and forms that must be maintained with the
production unit.production unit.
– Includes work instructions, recipes, drawings, standard operatingIncludes work instructions, recipes, drawings, standard operating
procedures (SOP), batch records, shift to shift communication.procedures (SOP), batch records, shift to shift communication.
– It sends instructions down to operations and device controlsIt sends instructions down to operations and device controls

17. 1717
MES Functionality (Contd.)MES Functionality (Contd.)
Performance AnalysisPerformance Analysis
– Provides real-time reporting of actual manufacturing operationsProvides real-time reporting of actual manufacturing operations
results along with comparisons to past history and expectedresults along with comparisons to past history and expected
results.results.
– Performance results include resource utilisation, resourcePerformance results include resource utilisation, resource
availability, cycle time, conformance to schedule and standards.availability, cycle time, conformance to schedule and standards.
– May include SPC / SQC analysisMay include SPC / SQC analysis
Operational Detail SchedulingOperational Detail Scheduling
– Provides sequencing based on priorities, attributes,Provides sequencing based on priorities, attributes,
characteristics and production rules.characteristics and production rules.
– It is finite and it recognises alternative and overlappingIt is finite and it recognises alternative and overlapping
operations to calculate timing of equipment loadingoperations to calculate timing of equipment loading
Resource Allocation & StatusResource Allocation & Status
– Manage the resources directly associated with control andManage the resources directly associated with control and
manufacturing.manufacturing.

18. 1818
MES Functionality (Contd.)MES Functionality (Contd.)
Labour ManagementLabour Management
– Provides status of personnel.Provides status of personnel.
– Includes time and attendance, certification tracking, asIncludes time and attendance, certification tracking, as
well as preparation work as basis for activity–basedwell as preparation work as basis for activity–based
costing.costing.
– May interact with resource allocation for optimalMay interact with resource allocation for optimal
assignments.assignments.
Maintenance ManagementMaintenance Management
– Functionality for maintaining equipment and tools.Functionality for maintaining equipment and tools.
– Ensures equipment and tools availability forEnsures equipment and tools availability for
manufacturing.manufacturing.
– May also include scheduling for periodic or preventiveMay also include scheduling for periodic or preventive
maintenance.maintenance.
– Maintains history of past events to aid in diagnosingMaintains history of past events to aid in diagnosing
problems.problems.

19. 1919
System / Response TimeSystem / 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. 2020
MES - VendorsMES - Vendors
ABB Automation Technology Products (www.abb.com)
GE Fanuc Automation (www.gefanuc.com)
Honeywell Hi-Spec Solutions (www.hispec.com)
Kronos Inc (www.kronos.com)
RockwellSoftware (www.software.rockwell.com)
Schneider Electric (/www.schneider-electric.com)
Siemens Energy & Automation (www.sea.siemens.com)
Tecnomatix Tecnologies (www.tecnomatix.com)

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Good LuckGood Luck
http://www.linkedin.com/in/anandsubramaniamhttp://www.linkedin.com/in/anandsubramaniam