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MES; SCADA; PLC

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Why MES?

• Missing link between PCS (Process

Control Systems) and corporatesystems (typically ERP)

• PCS attached to devices on factoryfloor

 –

Often proprietary technologies – Export data as text

 – Often left unconnected

 – Or managed by specialists (non-IT)

 – Critical systems (eg: BGE)

 –Requirement for compliance

• ERP does not finish where PCSbegins

• Invoke different competences

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Manufacturing Executive Systems

Includes shopfloor instrumentation, control hardware,planning and control systems, process engineering, inventory,

quality systems.

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Manufacturing Execution Systems (MES),

•are IT systems that manage manufacturing operations in factories.

Scope includes:

• Management of product definitions. Includes storage, version control and

exchange with other systems of master data like product production rules,

bill of material, bill of resources, process set points and recipe data all

focused on defining how to make a product. Management of productdefinitions can be part of Product lifecycle management 

• Management of resources. Includes registration, exchange and analysis of 

resource information, aiming to prepare and execute production orders

with resources of the right capabilities and availability.

• Scheduling (production processes). These activities determine production

schedule as a collection of work orders to meet production requirements,

typically received from Enterprise resource planning or specialized

Advanced planning & scheduling systems, making optimal use of local

resources.

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• Dispatching production orders. Depending on the type of production

processes this may include further distribution of batches, runs and work

orders, issuing these to work centers and adjustment to unanticipated

conditions.

• Execution of production orders. Although actual execution is done by

Process Control Systems (PCS), an MES may perform checks on resources

and inform other systems about the, progress of production processes.

• Collection of production data. includes collection, storage and exchange of 

process data, equipment status, material lot information and production

logs in either a data historian or relational database.

• Production performance analysis. Create useful information out of the raw

collected data about the current status of production, like Work In Progress

(WIP) overviews, and the production performance of the past period like the

Overall Equipment Effectiveness or any other Performance indicator.

• Production Track & Trace. Registration & retrieval of related information in

order to present a complete history of lots, orders or equipment (particularly

important in health related productions, e.g. pharmaceuticals)

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Relationship

Corporate

 Plant

MRP II/ ERP

MES

PLC Robots/ AGV

DCS

production planning,

scheduling

recipes

process setpoints

operating instructions

batch,

production run

reporting or

completion

actual process conditons,

completion of process steps

and operations, performance

of equipment and raw

material and operator

actions

Planning When/What to make

Planned/standard lead times/ 

yields/wastes/costs

Execution Production management/tracking

- WIP, equipment, operators Production scheduling

Quality control/SQC

Costing

Maintenance

Management functions -

Communications, reporting

Control Ladder logic

Continuous feedback 

PID

Advanced control

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ERP-MES-Control Data Flow

MPRII/ERP

Forecasting

Costing

Production Planning

Product Definition

Process Definition

SOPHuman Resources

Inventory Management

Purchasing

Distribution

MES

Resource Alloc./Status

Operations Scheduling

Production Dispatching

Document Control

Data Collection /Acq.

Labor ManagementWIP Status/Traceability

Quality Management

Performance Analysis

Process Management

Product Tracking

and Genealogy

Maintenance

Management

Order Status/COmpletion s

 /Start-D ue-E nd

Resource Status/Usage

Labor Status/Usage

Material Status/U sage

Actual BOM/Formula/Recipe/ 

Drawing/Part Program

Actual Routing/Process

Product Genealogy/Traceability

 /A s Bui lt In formatio n

Scrap/Waste

Product Demand

BOM/Formula/Recipe/Drawing

 /P art P rog ram

Resources

Routing/Process

Labor Characteristics

Inventory Status

SOP, HEALTH, WORK Instructions

Monitoring & SensingProcess

Equipment

Environment

Labor

Material

ControlMachine Control

Regulatory Control

Realtime QC

Advanced Process Controls

OperationsProcess Sequencing

Machine & Process Instructions

Labor Instructions

Human Machine Interfacing

Safety

Maintenance

Process I nstructions:Recipes,

Work Instructions , Part P rograms,

Order Specific, Machin e

Utilization , Work Certification

Requirements

Operator Instructions:Scheduled

(predictive) & Preventative

Maintenance,

Material Safety Instructions

(documents), Machine Operation

Instructions (documents)

Drill Down (inquiries) Status

Process Status

Ba tch End Reports

Ad Hoc Inquires

Materials Analysis

Events: Time/Date/Lot/Alarms

Data Collected from Monitoring

Functions: Process, Equi pment,

Environment, L abor, Material, P roduct

Parameters

Focus:

Customer

Decision Location:

Office

Focus:

Product

Decision Location:

Factory

Focus:

Process

Decision Location:

Shop Floor/Plant Floor

Planning Execution Control

MESA International-White Paper

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SCADA (Supervisory control and data acquisition)

Supervisory Control & Data Acquisition software gathers data in real-time tocontrol equipment and conditions.

These systems include hardware and software components to gather and present

manufacturing data for quality control, inventory management and productionplanning.

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SCADA

• generally refers to industrial control systems: computer systems that

monitor and control industrial, infrastructure, or facility-based processes,

as described below:

• Industrial processes include those of manufacturing, production, power

generation, fabrication, and refining, and may run in continuous, batch,

repetitive, or discrete modes.

• Infrastructure processes may be public or private, and include water

treatment and distribution, wastewater collection and treatment, oil and

gas pipelines, electrical power transmission and distribution, Wind farms,

civil defense siren systems, and large communication systems.

• Facility processes occur both in public facilities and private ones, including

buildings, airports, ships, and space stations. They monitor and control

HVAC, access, and energy consumption.

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SCADA System usually consists of following

subsystems:

• A Human-Machine Interface or HMI is the apparatus which presents

process data to a human operator, and through this, the human operator

monitors and controls the process.

• A supervisory (computer) system, gathering (acquiring) data on the

process and sending commands (control) to the process.

• Remote Terminal Units (RTUs) connecting to sensors in the process,

converting sensor signals to digital data and sending digital data to the

supervisory system.

• Programmable Logic Controller (PLCs) used as field devices because they

are more economical, versatile, flexible, and configurable than special-purpose RTUs.

• Communication infrastructure connecting the supervisory system to the

Remote Terminal Units.

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PLC: Programmable logic controller or

programmable controller

• is a digital computer used for automation of electromechanical processes,

such as control of machinery on factory assembly lines, amusement rides,

or lighting fixtures. Used in industries and machines.

• Unlike general-purpose computers, PLC is designed for multiple inputs and

output arrangements, extended temperature ranges, immunity to

electrical noise, and resistance to vibration and impact. Programs to

control machine operation are typically stored in battery-backed or non-

volatile memory.

• A PLC is an example of a hard  real time system since output results must

be produced in response to input conditions within a bounded time,

otherwise unintended operation will result.