This document summarizes different practices for managing engine assembly using manufacturing execution systems (MES) and programmable logic controllers (PLC). BMW's practice involves an OEM assembly management system that configures the process and downloads instructions to the PLC. Volkswagen's practice uses an MES to download order information, serial numbers, and process instructions directly to a PLC and 64KB RFID tag. Cummins' practice has the MES control the PLC in real-time by downloading order information to the PLC and writing to an RFID tag, and having the PLC get instructions from and upload data to the MES.

1. MES and Control in Engine Assembly
Tallrain / Jul 2017

2. Contents
1. Challenges
2. BMW Practice
3. Volkswagen Practice
4. Cummins Practice

3. 1. Challenges
 Plant Floor devices need to know which product to make.
 Plant Floor devices need to know how to build a product.
 MES needs to know how a product is actually built.

4. 2. BMW Practice: Based on AMS(OEM’s Assembly Management System)
AMS
1. Engineer
configures
process in AMS
MES
2. MES
downloads Order
& BOM
Into AMS
PLC
3. AMS downloads
Order & S/N
Into PLC,
And writes into
RFID in 1st station
4. Before assembly,
PLC reads S/N from
RFID, and get
instruction from AMS
5. After assembly,
PLC uploads data
into AMS, and
then sync to MES

5. 2. Volkswagen Practice: Based on MES & 64KB RFID
1. Engineer
configures
process in MES
MES
PLC
2. MES downloads
Order & S/N & Process
Instructions
Into PLC,
And writes into 64KB
RFID in 1st station
3. Before assembly,
PLC reads Station’s
Process Instructions
from 64KB RFID
4. After assembly,
PLC writes
process data into
64KB RFID
5. At last station,
PLC reads all
process data from
64KB RFID, and
sync to MES

6. 3. Cummins Practice: MES controls PLC in realtime
1. Engineer
configures
process in MES
MES
PLC
2. MES downloads
Order & S/N
Into PLC,
And writes into RFID in
1st station
3. Before assembly,
PLC reads S/N from
RFID, and get
instruction from MES
4. After assembly,
PLC uploads data
into MES

7. Thank you!