MES from the Ground Up
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Transcript of MES from the Ground Up
1
MES: A View from the Shop Floor
Edward Brown
What is MES?
The Big Bang Theory
Evolution not Revolution
Charting a Course
World Peace
MES from the Ground Up
Laying the Foundation
Build the Pyramids
Conclusion
2
What is MES?
The Big Bang Theory
Evolution not Revolution
World Peace
Charting a Course
Laying the Foundation
Build the Pyramids
Topics
What is MES?
The Big Bang Theory
Evolution not Revolution
Charting a Course
World Peace
MES from the Ground Up
Laying the Foundation
Build the Pyramids
Conclusion
3
ISA-95 Manufacturing Operations Model
ISA-95 part 3 defines MES/MOM capabilities
INVENTORYOPERATIONSMANAGEMENT
INVENTORYOPERATIONSMANAGEMENT
MAINTENANCEOPERATIONSMANAGEMENT
PRODUCTIONOPERATIONSMANAGEMENT
QUALITYOPERATIONSMANAGEMENT
Procurement(5.0)
ProductionScheduling
(2.0)
Material andEnergy Control
(4.0)
ProductInventory Control
(7.0)
Product CostAccounting
(8.0)
QualityAssurance
(6.0)
ResearchDevelopment
and Engineering
ProductShipping Admin
(9.0)
OrderProcessing
(1.0)
Marketing& Sales
ProductionControl
(3.0)
MaintenanceManagement
(10.0)
What is MES?
What is MES?
The Big Bang Theory
Evolution not Revolution
Charting a Course
World Peace
MES from the Ground Up
Laying the Foundation
Build the Pyramids
Conclusion
Trickle Down Theory
DefinedIn S95
Business Logistics SystemsPlant Production Scheduling
and Operational Management
Level 4
Manufacturing Control SystemsArea Supervision, Production
Scheduling, Reliability Assurance
Level 3
BatchControlSystems
DiscreteControlSystems
ContinuousControlSystems
Levels2,1,0 Defined
In S88
What is MES?
What is MES?
The Big Bang Theory
Evolution not Revolution
Charting a Course
World Peace
MES from the Ground Up
Laying the Foundation
Build the Pyramids
Conclusion
Information is the CurrencyWhat is MES?
What is MES?
The Big Bang Theory
Evolution not Revolution
Charting a Course
World Peace
MES from the Ground Up
Laying the Foundation
Build the Pyramids
Conclusion
Product Definition Information
Maintenance Information
Scheduling CapabilityInformation
Production CapabilityInformation
Scheduling information on production equipment, including information notrelated to production capability
Maintenance information on production equipment, including information not related to the production capability
Preventive/Predictive Maintenance Information
Scheduled Production equipment outages
Production equipment status
Production Capacity (Including equipment organization and product flows)
Production capability and capacity definition, is specific to an area, process cell, production unit, assembly line.
What is MES?
What is MES?
The Big Bang Theory
Evolution not Revolution
Charting a Course
World Peace
MES from the Ground Up
Laying the Foundation
Build the Pyramids
Conclusion
Production Capability Information
Maintenance
Information
SchedulingCapability
Information
ProductionCapability
Information
Scheduling information on production equipment, including information not related to production capability
Maintenance information on production equipment, including information not related to the production capability
Preventive/Predictive Maintenance Information
Scheduled Production equipment outages
Production equipment status
Production Capacity (Including equipment organization and product flows)
Production capability and capacity definition, is specific to an area, process cell, production unit, assembly line.
What is MES?
What is MES?
The Big Bang Theory
Evolution not Revolution
Charting a Course
World Peace
MES from the Ground Up
Laying the Foundation
Build the Pyramids
Conclusion
Production Information
InventoryInformation
SchedulingInformation
ProductionInformation
Scheduling information on production
Information on all inventoriedmaterial and equipment.
Production Schedule andProduction Performance
Production Line Item Information
Production information, is specific to an area, process cell, production unit, assembly line. (Batch Journal, log, …)
Production Material Information
What is MES?
What is MES?
The Big Bang Theory
Evolution not Revolution
Charting a Course
World Peace
MES from the Ground Up
Laying the Foundation
Build the Pyramids
Conclusion
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In the beginning there was nothing, and it exploded.
- Terry Pratchett
MES Implemented as a Large Footprint Application
Follows ERP implementation model (all functionality at once)
Can perform most or all functions in the MOM
Capability to pass information across all areas of the MOM model from/to ERP and PCS levels
Tightly integrated functional modules across manufacturing
Technology centric, business processes adjust to application procedures
The MES “Big Bang” Theory
The Big BangTheory
What is MES?
The Big Bang Theory
Evolution not Revolution
Charting a Course
World Peace
MES from the Ground Up
Laying the Foundation
Build the Pyramids
Conclusion
10
Significant Capital Investment Application Packages from 250K single site – 10M
enterprise
Significant Resource Investment Requires dedicated project teams and subject matter
experts
Duration of project can last from 6 months to 3 years
Significant IT, Management, Operator Training
Significant IT support for application life
Sticker Shock
The Big BangTheory
What is MES?
The Big Bang Theory
Evolution not Revolution
Charting a Course
World Peace
MES from the Ground Up
Laying the Foundation
Build the Pyramids
Conclusion
11
Significant Change Management Process Companies overestimate the understanding of their own
processes
Companies underestimate the impact of implementing new manufacturing and business processes
Resistance to change is often significant without comprehensive representation in designing process change
Difficult to predict full impact of change from one area to another
Change or Revolution?
The Big BangTheory
What is MES?
The Big Bang Theory
Evolution not Revolution
Charting a Course
World Peace
MES from the Ground Up
Laying the Foundation
Build the Pyramids
Conclusion
12
Long and Complicated Implementations Requirements, analysis, and design period can consume
significant portion of projected effort
Customizations can consume more than half of required project effort
External system interfaces can require significant effort of those systems IT personnel
A Long Hard Road
The Big BangTheory
What is MES?
The Big Bang Theory
Evolution not Revolution
Charting a Course
World Peace
MES from the Ground Up
Laying the Foundation
Build the Pyramids
Conclusion
13
Determining Return on Investment can be difficult
Good and Bad effects of integrated functions can make it difficult to determine specifics
Quality of requirements and design usually have bigger impact on ROI than the function itself.
Wrong low hanging fruit – Initial assumption of a high ROI function may be misguided
It Shouldn’t Be a Hedge Fund
The Big BangTheory
What is MES?
The Big Bang Theory
Evolution not Revolution
Charting a Course
World Peace
MES from the Ground Up
Laying the Foundation
Build the Pyramids
Conclusion
14
If one is master of one thing and understands one thing well, one has at the same time, insight into and understanding of many things.
- Vincent van Gogh
MES Implemented in Incremental Steps
Select one or few MOM capabilities to implement
Add MOM capabilities over time
Exchanges information with implemented features from/to ERP and PCS levels as required
Loosely coupled functional modules across manufacturing with the ability to leave legacy systems in place
Process centric approach using appropriate technology as needed through combination of customization and extension of existing systems and incorporating new technologies/applications
The Evolutionary Approach
Evolution not Revolution
What is MES?
The Big Bang Theory
Evolution not Revolution
Charting a Course
World Peace
MES from the Ground Up
Laying the Foundation
Build the Pyramids
Conclusion
15
Reasonable Capital Investment Pay for what you use – Smaller Technology Purchases
Supporting Infrastructure matched to technology – some increments may not require it
Reasonable Resource Investment Smaller Project teams and fewer subject matter experts
specific to capability and for shorter duration
Duration of project reduced, typically 3-6 months
Reduced IT, Management, Operator Training
Reduced IT support for new application(s)
Efficiency Drives Evolution
Evolution not Revolution
What is MES?
The Big Bang Theory
Evolution not Revolution
Charting a Course
World Peace
MES from the Ground Up
Laying the Foundation
Build the Pyramids
Conclusion
16
Simplified Change Management Process Concentrate on understanding one or a few processes
well
More time to understand the impact of implementing a new manufacturing and business process
Resistance to change can be reduced by including selective representation in designing process change
Easier to predict full impact of change from one area to another
A Welcome Change
Evolution not Revolution
What is MES?
The Big Bang Theory
Evolution not Revolution
Charting a Course
World Peace
MES from the Ground Up
Laying the Foundation
Build the Pyramids
Conclusion
17
Shorter and Simplified Implementations
Requirements, analysis, and design period scaled to MOM capability being implemented
Customizations limited to single/few capabilities
External system interfaces may not be required for some capabilities and are limited for those that are
Quick AND Easy?
Evolution not Revolution
What is MES?
The Big Bang Theory
Evolution not Revolution
Charting a Course
World Peace
MES from the Ground Up
Laying the Foundation
Build the Pyramids
Conclusion
18
Easier to Determine Return on Investment
Good and Bad effects of implemented capability are readily apparent
Quality of requirements and design are usually improved because scope is smaller and easier to understand
Low Hanging Opportunities can be evaluated quickly and expanded or contracted as required
Hard ROI evidence justifies next increment
ROI Clarity
Evolution not Revolution
What is MES?
The Big Bang Theory
Evolution not Revolution
Charting a Course
World Peace
MES from the Ground Up
Laying the Foundation
Build the Pyramids
Conclusion
19
Successful MES Projects are PROCESS Centric
Use the ISA-95 MOM model to determine activities for consideration
Determine the current state of the process thoroughly
Getting MES Processes Right is a TEAM Effort
MES isn’t an IT initiative, it’s a Team initiative
MES SUPPORTS Lean and Six Sigma Initiatives
The Right Representation for the Capability
Capabilities may dictate different SME’s, Operators, IT skills
One Team, One Manufacturing World
World Peace
Finding good players is easy. Getting them to play as a team is another story.
- Casey Stengel
What is MES?
The Big Bang Theory
Evolution not Revolution
Charting a Course
World Peace
MES from the Ground Up
Laying the Foundation
Build the Pyramids
Conclusion
20
Let our advance worrying become advance thinking and planning.
- Winston Churchill
Creating a Long Term Plan Document Business Goals and Objectives
Build Capabilities Pyramids to Achieve World Class Status
Identification of Low Hanging Opportunities
Collaboration Workshops to Develop Roadmap(s)
A Long Term Roadmap is Essential
Charting a Course
What is MES?
The Big Bang Theory
Evolution not Revolution
Charting a Course
World Peace
MES from the Ground Up
Laying the Foundation
Build the Pyramids
Conclusion
21
Business Goals and Objectives Initiatives Key Performance Indicators Objectives & Constraints Customer/Supplier Effectiveness
ISA-95 Activity Survey Conduct Surveys for candidate Department(s) Small SME Teams Complete ISA-95 Activity Survey
Determine Shortfalls by Activity Develop As-Is Process Flow Determine List of Shortfalls by Activity Determine Cost of Shortfalls
Create Measurable Objectives
Charting a Course
What is MES?
The Big Bang Theory
Evolution not Revolution
Charting a Course
World Peace
MES from the Ground Up
Laying the Foundation
Build the Pyramids
Conclusion
Clarify Objectives and Requirements
Charting a Course
What is MES?
The Big Bang Theory
Evolution not Revolution
Charting a Course
World Peace
MES from the Ground Up
Laying the Foundation
Build the Pyramids
Conclusion
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Best in Class is represented by companies who support ever increasing capabilities of:
Automation
Conversion of paper processes to electronic
Data capture through equipment and instrumentation
Minimizing Operator Input
Integration
Integrating functional data from operation to operation
Integrating functional data across capabilities
Integrating functional data across business units and plants
Build Capabilities to Reach Best In Class
Charting a Course
What is MES?
The Big Bang Theory
Evolution not Revolution
Charting a Course
World Peace
MES from the Ground Up
Laying the Foundation
Build the Pyramids
Conclusion
24
Develop capabilities that reflect Business Goals and Objectives
Build Capability Pyramids
Integration
Automation
Foundation
Goal
Best In Class
Laying the Foundation
What is MES?
The Big Bang Theory
Evolution not Revolution
Charting a Course
World Peace
MES from the Ground Up
Laying the Foundation
Build the Pyramids
Conclusion
25
Select Candidate Capabilities from Goals & Objectives
Map MOM Activities to Capabilities
Determine Automation Requirements
Determine Low Hanging Opportunities
Laying the Foundation
A successful man is one who can lay a firm foundation with the bricks others have thrown at him.
- David Brinkley
What is MES?
The Big Bang Theory
Evolution not Revolution
Charting a Course
World Peace
MES from the Ground Up
Laying the Foundation
Build the Pyramids
Conclusion
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Scenario: Operators at the Acme Drug Company add to the Batch Record at Compounding by physically attaching a paper trend chart for environmental conditions. On average, three incidents per Quarter occur where the incorrect chart data was associated with a Batch. Of those incident batches, one batch in three cannot be resolved and is lost.
Costs: Annual time and material4 quarters * 3 incidents = $15K-$50K
4 quarters * 1 batch/quarter = $1M - $5M
Opportunity $1M – $6M
A Genealogy MOM Capability Appears to be a Viable Candidate Project.
Identifying the Target
Laying the Foundation
What is MES?
The Big Bang Theory
Evolution not Revolution
Charting a Course
World Peace
MES from the Ground Up
Laying the Foundation
Build the Pyramids
Conclusion
27
Map MOM Activities to Capabilities
Laying the Foundation
What is MES?
The Big Bang Theory
Evolution not Revolution
Charting a Course
World Peace
MES from the Ground Up
Laying the Foundation
Build the Pyramids
Conclusion
28
Hold Workshop(s) for Selected Capability
Build the Pyramids
No one wants advice, only collaboration
- John Steinbeck
What is MES?
The Big Bang Theory
Evolution not Revolution
Charting a Course
World Peace
MES from the Ground Up
Laying the Foundation
Build the Pyramids
Conclusion
Process Maps are the Foundation
Build the Pyramids
What is MES?
The Big Bang Theory
Evolution not Revolution
Charting a Course
World Peace
MES from the Ground Up
Laying the Foundation
Build the Pyramids
Conclusion
Determine Automation Data Requirements
Build the Pyramids
What is MES?
The Big Bang Theory
Evolution not Revolution
Charting a Course
World Peace
MES from the Ground Up
Laying the Foundation
Build the Pyramids
Conclusion
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Quality Data Collection & Tracking
Collect and Associate Quality Test results with Batch
Lot Management
Record Consumption of Raw Material Lots
Material Tracking
Record movement of materials from location to location
Production Execution
Record Environmental Data to Historian
Record CIP/SIP Data to Historian
Record and Associate production data with Batch Record
Genealogy Automated Data Collection
Build the Pyramids
What is MES?
The Big Bang Theory
Evolution not Revolution
Charting a Course
World Peace
MES from the Ground Up
Laying the Foundation
Build the Pyramids
Conclusion
32
Using or expanding the Automation functions you already have is a smart way to achieve MES functionality
What’s in the Backyard?
Build the Pyramids
What is MES?
The Big Bang Theory
Evolution not Revolution
Charting a Course
World Peace
MES from the Ground Up
Laying the Foundation
Build the Pyramids
Conclusion
A MES Repository Aggregates & Associates
Build the Pyramids
What is MES?
The Big Bang Theory
Evolution not Revolution
Charting a Course
World Peace
MES from the Ground Up
Laying the Foundation
Build the Pyramids
Conclusion
34
Provide MES Repository Structure for Capability Associations
Allow individual MOM Capabilities to Utilize Structures and Associations as needed
Add Capabilities by Exposing Additional MES Associations and Structures
$60K-$300K Typical Installed Cost
Extendable MES Requirements
Build the Pyramids
What is MES?
The Big Bang Theory
Evolution not Revolution
Charting a Course
World Peace
MES from the Ground Up
Laying the Foundation
Build the Pyramids
Conclusion
Map Functions to Technologies
Build the Pyramids
What is MES?
The Big Bang Theory
Evolution not Revolution
Charting a Course
World Peace
MES from the Ground Up
Laying the Foundation
Build the Pyramids
Conclusion
36
Justify the Necessity
Build the Pyramids
What is MES?
The Big Bang Theory
Evolution not Revolution
Charting a Course
World Peace
MES from the Ground Up
Laying the Foundation
Build the Pyramids
Conclusion
37
Extend Legacy Systems where appropriate
Develop Automation capability where necessary
Implement limited MES functionality with compartmentalized capabilities
Establish and Monitor Process Improvement Metrics
Measure and Document ROI
Use ROI to Justify Next Brick
Implement and Evaluate
Build the Pyramids
Plans are only good intentions unless they immediately degenerate into hard work.
- Peter Drucker
What is MES?
The Big Bang Theory
Evolution not Revolution
Charting a Course
World Peace
MES from the Ground Up
Laying the Foundation
Build the Pyramids
Conclusion
Build on Capabilities
Build the Pyramids
What is MES?
The Big Bang Theory
Evolution not Revolution
Charting a Course
World Peace
MES from the Ground Up
Laying the Foundation
Build the Pyramids
Conclusion
39
Growing MES Provides a Reasonable Alternative
Reasonable Capital Investment
Reasonable Resource Investment
Simplified Change Management Process
Shorter and Simplified Implementations
Easier to Determine Return on Investment
Process is More Important than Technology
Determine Ripe Opportunities
Include All Stakeholders in Collaboration Workshops
Conclusions
Conclusion
What is MES?
The Big Bang Theory
Evolution not Revolution
Charting a Course
World Peace
MES from the Ground Up
Laying the Foundation
Build the Pyramids
Conclusion
40
Capability Pyramids Provide Context
Clearly Defines Goals and Necessary Elements for Growth
Automation can Provide MES capabilities
Current Automation Data Aggregated to MES DB
Extending Automation Capability can be more Efficient
Measuring Performance Justifies Next Steps
KPI’s Show Operational Improvements for Change Management
ROI Measurements provides Business Case for additional capability
Conclusions
Conclusion
41
Questions?
Web Site: www.AvidSolutionsInc.com
Contact Information:
Ed Brown – 919.606.9592
Shane Bernard– 336.409.9894