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Transcript of 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