MES - CASE STUDY
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NOMBRE: Milton Fonseca CONTROL DE LA CALIDAD INDUSTRIAL FECHA: 06 de Agosto del 2015 MANUFACTURING EXECUTION SYSTEMS (MES) NRC: 2119 DEFINITION A manufacturing execution system (MES) is a control system for managing and monitoring work-in-process on a factory floor. An MES keeps track of all manufacturing information in real time, receiving up-to-the-minute data from robots, machine monitors and employees. Although manufacturing execution systems used to operate as self-contained systems, they are increasingly being integrated with enterprise resource planning (ERP) software suites. The goal of a manufacturing execution system is to improve productivity and reduce cycle-time, the total time to produce an order. By integrating an MES with ERP software, factory managers can be proactive about ensuring the delivery of quality products in a timely, cost-effective manner. (Rouse, 2012) Manufacturing Execution Systems create flawless manufacturing processes and provide real-time feedback of requirement changes, and provide information at a single source. Other benefits from successful MES implementation might include: Reduced waste, re-work and scrap, including quicker setup times More accurate capture of cost-information (e.g. labor, scrap, downtime, and tooling) Increased uptime Incorporate Paperless Workflow Activities Reduced inventory, through the eradication of just-in-case inventory CASE STUDY: MES - Manufacturing Execution Systems support LEAN Manufacturing empowering shop floor personnel to take real-time decisions. For Fast Moving Consumer Goods (FMCG) manufacturers, in particular within the food & beverages, beauty, pharmaceutical and industrial sectors, margins continue to be under increasing pressure. Continued price increases in raw materials, energy and personnel cost can only partially be passed on, as consumers are becoming more cost conscious. The supplies of low cost, discounted or cheaper trade products make it more difficult for brand manufacturers to survive under the current market conditions. Hence, in order to maintain or grow profitability and fulfil shareholder value expectations, the bigger portion of these increases has to be absorbed internally and counterbalanced by efficiency improvements. This case study describes the benefits of a strategic implementation of software packages like Manufacturing Execution Systems (MES) to effectively reduce cost, and specifically minimise production losses in downtimes, quality and speed. One of those MES products on the market is Factory MES, formerly known as CDCFactory MOM, created by the US company APTEAN. It is designed to transform manufacturing performance by empowering people to make real-time actionable decisions. By standardizing the best practices of lean manufacturing, OEE (Overall Equipment Effectiveness) and Continuous Improvement, Factory MES Figure 1MES Components Figure 2OEE - Loss visualization Figure 3Performance of Home page
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MES - CASE STUDY
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Figure 1MES ComponentsFigure 2OEE - Loss visualizationFigure 3Performance of Home pageNOMBRE: Milton FonsecaCONTROL DE LA CALIDADINDUSTRIALFECHA: 06 de Agosto del 201MANUFACTURINGEXECUTION SYSTEMS (MES)NRC: 211!DEFINITIONA "an#$act#%ing e&ec#tion s'ste" (MES) is a cont%ol s'ste" $o% "anaging and "onito%ing *o%+,in,-%ocess on a $acto%' $loo%. AnMES+ee-s t%ac+o$ all "an#$act#%ingin$o%"ationin%eal ti"e/ %ecei0ing#-,to,t1e,"in#tedata$%o"%o2ots/ "ac1ine"onito%s ande"-lo'ees. Alt1o#g1 "an#$act#%ing e&ec#tion s'ste"s #sed to o-e%ate as sel$,contained s'ste"s/ t1e' a%e inc%easingl' 2eing integ%ated *it1ente%-%ise %eso#%ce -lanning (ER3) so$t*a%e s#ites. T1e goal o$ a "an#$act#%ing e&ec#tion s'ste" is toi"-%o0e -%od#cti0it' and %ed#ce c'cle,ti"e/ t1e total ti"e to -%od#ce an o%de%. 4' integ%ating an MES*it1 ER3 so$t*a%e/ $acto%' "anage%s can 2e -%oacti0e a2o#t ens#%ing t1e deli0e%' o$ 5#alit' -%od#cts in ati"el'/ cost,e$$ecti0e "anne%. (Ro#se/ 2012)Man#$act#%ingE&ec#tionS'ste"sc%eate$la*less"an#$act#%ing-%ocessesand-%o0ide%eal,ti"e $eed2ac+ o$ %e5#i%e"ent c1anges/ and -%o0ide in$o%"ation at a single so#%ce. Ot1e% 2ene$its $%o"s#ccess$#l MES i"-le"entation "ig1t incl#de: Red#ced *aste/ %e,*o%+ and sc%a-/ incl#ding 5#ic+e% set#- ti"es Mo%e acc#%ate ca-t#%e o$ cost,in$o%"ation (e.g. la2o%/ sc%a-/ do*nti"e/ and tooling) Inc%eased #-ti"e Inco%-o%ate 3a-e%less 6o%+$lo* Acti0ities Red#ced in0ento%'/ t1%o#g1 t1e e%adication o$ 7#st,in,case in0ento%'CASE STUDY: MES - Manufacturin E!"cuti#n S$%t"&% %u''#rt (EAN Manufacturin "&'#)"rin %*#' f+##r '"r%#nn"+t# ta," r"a+-ti&" -"ci%i#n%.Fo% Fast Mo0ing Cons#"e% 8oods (FMC8) "an#$act#%e%s/ in -a%tic#la% *it1in t1e $ood 92e0e%ages/ 2ea#t'/ -1a%"ace#tical and ind#st%ial secto%s/ "a%gins contin#e to 2e #nde% inc%easing-%ess#%e. Contin#ed -%ice inc%eases in %a* "ate%ials/ ene%g' and -e%sonnel cost can onl' -a%tiall' 2e-assed on/ as cons#"e%s a%e 2eco"ing "o%e cost conscio#s. T1e s#--lies o$ lo* cost/ disco#nted o%c1ea-e% t%ade -%od#cts "a+e it "o%e di$$ic#lt $o% 2%and "an#$act#%e%s to s#%0i0e #nde% t1e c#%%ent"a%+et conditions. :ence/ in o%de% to "aintain o% g%o* -%o$ita2ilit' and $#l$il s1a%e1olde%0al#e e&-ectations/ t1e 2igge% -o%tion o$ t1ese inc%eases 1as to 2e a2so%2ed inte%nall' andco#nte%2alanced 2' e$$icienc' i"-%o0e"ents. T1is case st#d' desc%i2es t1e 2ene$its o$ ast%ategic i"-le"entationo$ so$t*a%e-ac+ages li+e Man#$act#%ingE&ec#tionS'ste"s(MES) to e$$ecti0el' %ed#ce cost/ and s-eci$icall' "ini"ise -%od#ction losses indo*nti"es/ 5#alit' and s-eed. One o$ t1ose MES -%od#cts on t1e "a%+et is Facto%' MES/$o%"e%l'+no*nas CDCFacto%'MOM/ c%eated2't1e USco"-an'A3TEAN. It isdesigned to t%ans$o%""an#$act#%ing -e%$o%"ance 2'e"-o*e%ing-eo-le to"a+e %eal,ti"e actiona2le decisions. 4' standa%di;ing t1e 2est -%actices o$ lean "an#$act#%ing/ OEE(O0e%all E5#i-"ent E$$ecti0eness) and Contin#o#s I"-%o0e"ent/ Facto%' MES -%o0ides a%eal,ti"e $%a"e*o%+t1atinteg%ates sc1ed#ling/o-e%ations/ 5#alit' and "aintenance.Ast1e s'ste"is an o#t,o$,t1e,2o& s'ste"/ *1ic1 is tailo%ed and con$ig#%ed to eac1c#sto"e%
