ManufacturingExecutionSystem-12360484152-phpapp02

7/27/2019 ManufacturingExecutionSystem-12360484152-phpapp02

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Manufacturing Execution

Systems (MES)

Why MES ?

Anand Subramaniam


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Highlights

Terms & Conceptual Overview

Relationship & Data Flow - ERP, MES & CIM

Why MES?

Business Drivers / Benefits

MES Components

ISA 95

MES

High Level Functionality

System / Response Time

MES Vendors


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Terms - ERP, MES & CIM

ERP systems handle financial functions, customerorders and send production requests to thefactory floor.

MES provide overall control and management ofthe factory floor, and provide updatedinformation to ERP systems.

The simplest model of CIM has MES as the middleground between ERP systems and individualmachine and automation controls


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Conceptual Overview

Relationship

Management

Enterprise

Resource

Planning

Manufacturing Execution

Systems

Process

ControlAsset

Optimisation

Customer / Vendor / Employee

Production

Planning &

Scheduling

RoboticsMotors &

Drives

Sensors

& Meters

Power

Electronics

Enterprise

Management

Factory

ManagementAutomation

and Control

Process

Measurement,

Actuation,

Energy

Distribution

Enterprise

Asset

Management

Real-TimeSystems

Transaction

Systems

Transformers

Switchgear


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Business Systems


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Computer Integrated Manufacturing


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Relationship - ERP & MES

Corporate

Plant

MRP II/ERP

MES

PLCRobots/AGV

DCS

production planning,scheduling

recipesprocess setpoints

operating instructions

reporting or

batch,production run

completion

,

Planningl When/What to make

l Planned/standard lead times/

yields/wastes/costs

Executionl Production management/tracking

- WIP, equipment, operators

l Production scheduling

l Quality control/SQC

l Costing

l Maintenance

l Management functions -

Communications, reporting

Controll Ladder logic

l Continuous feedback

l PID

l Advanced control

actual process conditons

completion of process steps

and operations, performance of

equipment and raw material &operator actions


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Data Flow ERP & MES

MESA International-White Paper

MPRII/ERP

Forecasting

Costing

Production Planning

Product DefinitionProcess Definition

SOP

Human Resources

Inventory Management

Purchasing

Distribution

MES

Resource Alloc./Status

Operations Scheduling

Production Dispatching

Document ControlData Collection/Acq.

Labor Management

WIP Status/Traceability

Quality Management

Performance Analysis

Process Management

Product Tracking

and Genealogy

Maintenance

Management

Monitoring & SensingProcess

Equipment

Environment

Labor

MaterialControl

Machine Control

Regulatory Control

Realtime QC

Advanced Process Controls

OperationsProcess Sequencing

Machine & Process Instructions

Labor Instructions

Human Machine Interfacing

SafetyMaintenance

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 InformationScrap/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

RequirementsOperator 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/AlarmsData Collected from Monitoring

Functions: Process, Equipment,

Environment, Labor, Material, ProductParameters

Focus:

CustomerDecision Location:

Office

Focus:

ProductDecision Location:

Factory

Focus:

ProcessDecision Location:

Shop Floor/Plant Floor

Planning Execution Control


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Why MES?

MES have evolved to fill thecommunication gap between themanufacturing planning system (MRP,

ERP, etc.) and the control systems to runequipment on the plant floor.

Co-ordinate functions on the shop floor

to optimise the plant activities

Provide visibility and flexibility to

effectively manage supply chain


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Business Drivers

Standard processes to enablebenchmarking and best practices

Seamless Integration

Resource Utilisation

Consistent Documentation

Visibility of data globallyAccurate and consistent measurementand reporting


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BenefitsIncreases Operational Excellence

Improves Asset Utilisation and the Management ofAssets

Benefits as listed by Manufacturing EnterpriseSolutions Association (http://www.mesa.org) Reduces manufacturing cycle time Reduces or eliminated data

Reduces work-in-process

Reduces or eliminated paperwork between shifts Reduces lead times Improves product quality Eliminated lost paperwork

Empowers plant operations people
http://www.mesa.org/http://www.mesa.org/http://www.mesa.org/


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MES Components

Core Material and Production Tracking

Material Handling and Production Procedures

Resource management and allocation

Production Dispatching

Data Collection

Extensions Compliance

Quality Assurance

Performance Analysis

Detail Scheduling

Document Management

Labor Management


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ISA 95

ISA = Instrumentation, Systems, andAutomation Society (ISA) Standard

Standard that defines how to linkEnterprise systems with MES layer. The MES Functionality

The Data base schema at the MES Level

The Messages between the Enterprise systemand MES


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Business Functions

Demand

PlanningSupply 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


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MES FunctionalityDispatching and Production Manages the flow of production in the form of jobs, orders,

batches, lots and work orders by dispatching production tospecific equipment and personnel.

Includes information that is presented in the sequence in whichthe work needs to be done.

Quality Management Provides real-time measurements collected form manufacturing

to assure proper product quality control and to identify problemsrequiring attention.

Includes SPC / SQC tracking and management of offline

inspection operations

Data Collection & Acquisition Obtains operational production and parametric data associated

with production equipment and processes. Provides real-time statuses of production equipment and

processes


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MES Functionality (Contd.)Process Management 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 handleprocess deviations

Production Tracking & Genealogy Provides status of production and disposition of work. Status information may include personnel, materials used,

current production conditions. Includes recording of productioninformation to allow forward and backward traceability.

Document Control Control records and forms that must be maintained with the

production unit. Includes work instructions, recipes, drawings, standard operating

procedures (SOP), batch records, shift to shift communication. It sends instructions down to operations and device controls


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MES Functionality (Contd.)Performance Analysis Provides real-time reporting of actual manufacturing operations

results along with comparisons to past history and expectedresults.

Performance results include resource utilisation, resourceavailability, cycle time, conformance to schedule and standards.

May include SPC / SQC analysis

Operational Detail Scheduling Provides sequencing based on priorities, attributes,

characteristics and production rules. It is finite and it recognises alternative and overlapping

operations to calculate timing of equipment loading

Resource Allocation & Status Manage the resources directly associated with control and

manufacturing.


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MES Functionality (Contd.)Labour Management Provides status of personnel. Includes time and attendance, certification tracking, as

well as preparation work as basis for activitybasedcosting.

May interact with resource allocation for optimalassignments.

Maintenance Management Functionality for maintaining equipment and tools.

Ensures equipment and tools availability formanufacturing. May also include scheduling for periodic or preventive

maintenance. Maintains history of past events to aid in diagnosing

problems.


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System / Response Time

Planning

Level

ExecutionLevel

Control

Level

Supervisory

Level

ms seconds hours days weeks month years

ERP(Enterprise Resource Planning)

DCS(Distributed ControlSystem)

MES(Manufacturing Execution System)

PLC(Programmable Logic

Controller)

SCADA(Supervisory Control and Data

Acquisition)


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MES - VendorsABB 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)
http://www.kronos.com/http://www.sea.siemens.com/http://www.sea.siemens.com/http://www.kronos.com/


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Good Luckhttp://www.linkedin.com/in/anandsubramaniam
http://www.linkedin.com/in/anandsubramaniamhttp://www.linkedin.com/in/anandsubramaniam

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