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TRACKING PROCESSES.REDEFINING EFFICIENCY.An Intelligent Approach to Manufacturing
MANUFACTURING EXECUTION SYSTEM
Engineering,Research &
Development
PRODUCTDEVELOPMENTIS AT THE CORE
OF EVERYTHINGWE DO
We empower our clients to make their product
dreams a reality by designing, engineering, validating
and industrialising better products.
Unlike any other organisation in our sector, beyond
engineering and product development, we've had the
curiosity to pursue the optimisation of end to end
manufacturing. The result is a complete
understanding of the benefits associated with the
digitalisation of modern manufacturing.
Architected well, the complete product realisation
lifecycle is a virtuous feedback loop designed to
embrace the data that supports the continuous
improvement of better products.
Tata Technologies leverages over 25 years of cumulative knowledge
and experience to help the world's leading manufacturers to create
great products and to select, deploy and adopt the technologies that
underpin the entire product realisation lifecycle. Drawing on a
combination of people, process and technology, we drive efficiencies
and innovation to help our clients meet the design, engineering and
production challenges.
CONNECTING THEMANUFACTURINGENTERPRISEConnected Enterprise IT solutions from Tata
Technologies enables businesses to optimise the
application of technology for the manufacturing
sector, removing critical data discontinuities and
enabling a platform for the complete digitalisation
of modern manufacturing. Our vast experience of
product development and manufacturing
engineering helps provide enterprise-wide visibility
of the key performance indicators of seamless
manufacturing execution.
WHY TATA TECHNOLOGIES?
• Enabling smart connected factories
• Delivering global solutions for digital manufacturing
• Extending the digital lifecycle into effective manufacturing with
ERP, MES, SCM, CXM, businesswide analytics and intelligence,
complemented by world-class Application Maintenance Services (AMS)
• Other legacy IT systems
CONNECTED
ENTERPRISE IT
SOLUTIONS(CEIT)
Manufacturing Enterprise IT
Process to Create
Capacity to Create
Manufacturing Execution System
For companies to achieve sustainable competitive
advantage in today's rapidly changing business
environment, they must deploy Intelligently different
solutions that respond to market changes both quickly
and effectively and help adopt production processes – in
real-time. A critical tool to achieve this is an efficient
manufacturing execution system (MES) that supports
timely execution.
Reduced time-to-market, demand for lower costs,
enhanced productivity and quality, maintaining track,
trace and genealogy records and a robust materials
management system are the challenges the
manufacturing industry is facing today. Fierce global
MANUFACTURE INTELLIGENTLY BY IMPROVINGDECISIONS FROM SHOP FLOOR TO TOP FLOOR
OPTIMISED PROCESSES.
SMARTER MANUFACTURING.
competition, rapidly changing business environments, cost
pressures, improving quality and increasingly complex
supply chains that need to be managed with agility are
major issues manufacturers around the globe are
constantly addressing. Demand changes driven by global
markets are highly volatile and therefore it is beneficial for
an organisation to implement a flexible, agile and robust
manufacturing operations management system. Customer
satisfaction, profitability in a cost-effective manner and
ensuring delivery commitments are the need of the hour
and therefore MES provides complete visibility and
control over their shop floor operations apart from a
tighter control on supply chain.
Tata Technologies delivers customised
Manufacturing Execution Systems (MES)
that enable informed decision-making and
identification of opportunities for improving
the production process. Deep domain
knowledge about complex manufacturing
processes, business issues and the
technologies required to improve
operational efficiencies are what our
practitioners specialise at. Backed by a
value-focused approach to ensure ongoing
simplification and Total Cost of Ownership
(TCO) reduction, our Subject-matter
Expertise is testimony to our 25+ years of
close association with leaders in the
automotive, aerospace and industrial heavy
machinery manufacturing sphere. Our
innovative capabilities and best-of-the-
breed consulting and implementation
services for MES solutions deliver
immediate business value and enable
organisations to realise the power of the
integrated enterprise, ultimately resulting in
business growth.
LEADING EDGE
SEE YOUR SHOP FLOOR LIKE NEVER BEFORE
Reduced manufacturing
cycle time by an average of
45%
Reduced data entry time by
75%
Reduced Work In Progress
(WIP) by an average of
24%
Reduced lead time by an
average of
27%
Reduced paperwork between
shifts by an average of
61%
Reduced product defects
by an average of
18%
Industry surveys recommend that businesses implementing and using an MES experience quantifiable changes
in profitability, quality, productivity and process performance. These can be summarised as shown below:
OURVALUE
PROPOSITION
Solution Roll-out• Multi-site Roll-out• Platform Migrations• Program/Project Management• Change Management
Integration Capabilities• MES-ERP• MES-Control System/CNC Integration• ISA 95 - Standard• Custom Integration
Consulting• MES Scan• Opportunity Assessment• MES Technology Product Evaluation• MES Consulting-IT and Automation Integration Landscape
Solution Design and Implementation Approach• Standard COTS Products Based Solution• Modular and Comprehensive• State-of-the-Art
Reporting Solutions• Standard Reports and Dashboards• KPI Measurement/ Operational Intelligence• Email Notifications• SMS Alerts
AMS Multi Level Support• Onsite• Offshore• Onsite/Offshore Mixed
Manufacturing Execution System
SERVICE OFFERINGS
Integration and InterfacesProduction Order Management
Performance Management
• Shop Floor Control Systems
Test Equipment and Data•
Loggers, LIMS
Enterprise Resource Planning•
PLM•
SCM•
Warehouse Management•
IT Systems•
• Data sources - Excel, Access,
SQL, Oracle
• Mobility Solutions
• Make To Stock (MTS) and Make
To Order (MTO)
Work Order Management•
Scheduling and Resequencing,•
Substitution and Dispatching
Work Order Broadcasting•
Materials Flow and Complex•
Routings (Rework/Repair)
Work Order Visibility•
Throughput Management•
Production Monitoring and Control•
• Reporting
Enables Plant Operations Visibility•
Overall Equipment Efficiency• (OEE)
Process and Plant KPIs•
Production and Downtime Reporting•
Product History and Analytics•
ANDON and Real-time Annunciation•
Maintenance Management•
Facility Monitoring and Controls
Inventory Management Quality Management
• Energy Monitoring and
Consumption Optimisation
Utilities Management•
Real-time Consumption Trends•
Warning Alerts•
Safety Alerts•
Consumption Reporting and•
Billing Management
Carbon Footprint Reduction•
• Kitting Accuracy
Kanban/JIT/JIS•
Line Side/Workstations/•
Inventory Management
Super Markets Management•
Vendor Managed Inventory (VMI)•
• In-line Quality
End of Line Quality •
Quality Containment•
Closed Loop Quality Control•
Defect Capture and Analysis•
SPC•
Regulator Compliance•
Lean/WCQ/TPM•
Audit Trail•
ERP
Industrial loT
MES
» Rockwell Automation
» GE
(Tata Technologies Customised Application)
Domain
» Automotive
» FMCG
» Industrial Heavy Machinery» Tyre
Sh
op
Flo
or
ERP
MES
» MS SQL
» Oracle
Database
» Factory Magix
PLC
»
» Siemens
RockwellAutomation
SCADA
» Siemens
» GE
» RockwellAutomation
Track, Trace and Genealogy Error Proofing
Real-time Production Tracking with•
Build history
Machine, Operation Status, WIP•
Visibility
Capturing Critical Process Values•
Operator Accountability in Decision•
Support
Material Traceability (Lot/Serial)•
Data Capturing of Critical Parts•
and Aggregates
Child Parts to Final Product•
Consumption/Raw Material•
Warranty and Recall Management•
• Pick to Light
Digital Work Instructions•
(DWI) for Quality Procedures
Poka-Yoke•
Autonomation•
Test and Inspection•
Manufacturing Execution System
BETTER SOLUTIONS.
BETTER OUTCOMES.
Alignment with BusinessObjectives
Innovation and BusinessTransformation
Solution Quality, Flexibilityand Speed
ComprehensiveCoverage
Enablers Transform Realise Enable Enablers
Inputs
Work Streams
Deliverables
Jump Start Launch Operational Excellence Strategic Solutions
Objectives
Tata Technologies Differentiator
Reduced Total Costof Ownership (TCO)
Focus on Business
Objectives and Value Drivers
Industriali ation ofsRelevant es Practice B t Process for Business
Aligned Solutions
Leveraging the Right Shorefor Delivery to Drive aFiscally Responsible’‘
Solution
Effective euse of xistingR EAssets to nsure ualityE Q
and peedy DeliveryS
ComplementaryTeaming
greements forAE -End-to nd
overageC
OUR MANUFACTURING EXECUTION SYSTEMSFRAMEWORK SOLUTION FRAMEWORK
PeopleDomain ExpertsProcess OwnersSMEs
ProcessGovernanceCommunicationQualityDelivery Metrics
InfrastructureScalable Data LineSecured ODECFailover and ClusteringVirtualisation
AlliancesSolution Partners-RockwellAutomation and GEIP
Tools
PLCAllen Bradley, Siemens,GE, Omron, Mitsubishi
SCADARockwell FT View,Siemens WinCC, GECimplicity, BeijerElectronics
Automation/DataExchange ProtocolsDeviceNet, Ethernet IP,Profibus, Profinet, Modbus, OPC
MESRA-FTPC, GE-Proficy,TTL-FM, IPMS, SAP
MES and ERPIntegrationMethodologyRFC, FTP, IntermediateDB Tables, CSV,Standard Connectors
MES SCAN
RFQ
Deliver MES KPI, Resources and Operational Targets
Opportunities of Improvements, Strategic Inputs from Identified Roadmap
Define
Plan
Execute
Verify
Business Analysis,
Definition, Design,
Development, Testing,
Deployment, Verification,
Sustain
Improvement Process
Continuous Improvement
Functional Requirement Specs, Timeline, Alignment, Value Driven Analysis
Optimised Delivery Model, Metrics Report, Improved Client Experience, Quality, Efficiency, Reduced Maintenance
Improved Time to MarketEnhanced ProductivityImproved Throughput
Our Manufacturing Execution Systems(MES) solutions help businesses respond to market changes both quickly and
effectively and help adopt production processes – in real-time. Implementing MES ensures complete visibility and
control over their shop floor operations apart from a tighter control on supply chain thus allowing the clients to take
better decisions. We develop customised line-of-business applications to meet the organisation's business objectives and
ensure quick and cost-effective implementation.
1050+ man years of ManufacturingExecution Systems (MES)
implementation experience
150 specialised resourcesin the MES practice
Key technology partners with Oracle, Rockwell
Automation and Microsoft
KEY DRIVERS TO SUCCESS
Manufacturing Execution System
ACCELERATING PROGRESS.
DRIVING RESULTS.
VALUEDELIVERED
Tata Technologies partnered with the industrial giant in India to
establish shop floor to top floor connectivity which could provide end-
to-end visibility across the in-bound and outbound enterprise supply
chain scenario.
THE COMPANYA Swedish industrial company,
manufacturing industrial tools and
equipment. It is considered as a world-
leader in providing sustainable productivity
solutions and serves customers in over 180
countries with products and services
focused on energy efficiency, safety and
ergonomics. The company has operational
centers spread across 20 locations within
India and features among the most
innovative companies around the world.
“During the integration of our supply systems with the shop floor and
supply chain, our top management required a dashboard on a web-
based application which could help them monitor the activities at the
ground level with a click of a button, either from office premises or
from external locations. The team at Tata Technologies did an
exceptional job and we have taken a unanimous decision of
implementing a similar system upgrade at another plant location too.”
-Plant Head, An Indian subsidiary of a Swedish
industrial company
CHALLENGE
The client had a non-integrated IT system which posed
challenges at the shop floor and information was present
in silos at different locations within a plant.
High Work In Progress (WIP) at sub-assembly levels,
which resulted in blocked capital
Leveraging its existing presence and small customer base
to propel sales of the new product line
Generating hype for the new product line by identifying a
healthy sales pipeline
SOLUTIONA custom-built application to provide end-to-end
manufacturing solutions inclusive of interface and
integrations with ERP, shop floor control system, third
party logistics, supermarket and finished goods yard
System deployed across two flexible assembly plants –
Make To Order (MTO) configurable products
Implementation of key functionalities notably order
management, kitting, pick list generation, JIT/JIS, e-
Kanban, ANDON system, genealogy, traceability, torque
and test data logging, digital work instructions and
finished goods yard management, pick-list and barcode
printing, real-time updates via reports, dashboards and
RESULTS
Sub-assembly WIP reduction from
three days to four hours
Single version of truth – Meeting
Time Reduction (MTR)
Product planning improvement by 30%
Manufacturing Execution System
©Copyright 2016 Tata Technologies. All rights reserved.
NORTH AMERICAEleven Mile Road41050 W. Novi, MI
USA48375
Tel. +1 2484261482
EUROPEThe Enterprise Centre
Coventry University Technology ParkPuma Way, Coventry, UK
CV12TTTel. +44 (0) 8443 759685
ASIA-PACIFIC 25, Rajiv Gandhi Infotech Park
Hinjawadi, PuneIndia
411057Tel. +91 20 6652 9090
Making dreams a reality since 1989.product development
ABOUT TATA TECHNOLOGIES
www.tatatechnologies.com@TataTech_News linkedin.com/company/tata-technologies
16 Global Delivery CentresDetroit - Novi, Detroit - Troy, Chicago (USA), Coventry & Bristol (UK), New Delhi, BlueRidge Pune, Hinjawadi Pune, Bengaluru & Thane (India), Bangkok (Thailand), Brasov, Craiova & Iasi (Romania), Shanghai (China) and Singapore
8,500+ Professionals
Europe, North America,Asia-Pacific
3 Regions
Tata Technologies, founded in 1989, enables ambitious
manufacturing companies to design and build better products
through engineering services outsourcing and the application of
information technology to product development and
manufacturing enterprise processes.
With over 8,500 professionals, representing 28 nationalities, Tata
Technologies focuses on the manufacturing industry - covering
every aspect of the value chain from conceptualisation,
manufacturing, aftermarket and maintenance repair overhaul
support. Tata Technologies supports clients through engineering
services outsourcing, product development, IT services and
product management solutions.
Tata Technologies serves clients in 27 countries, with a delivery
model specifically designed for engineering and IT engagements
that offers a unique blend of deep, local expertise integrated with
16 global delivery centres across Europe, North America and Asia
Pacific.