Manufacturing Execution System (Why MES?)

Manufacturing Execution Systems

1. 1
Manufacturing Execution
Systems (MES)
Why MES ?
Anand Subramaniam

2. 2
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

3. 3
Terms -ERP, MES & CIM
ERP systems handle financial functions, customer
orders and send production requests to the
factory floor.
MES provide overall control and management of
the factory floor, and provide updated information
to ERP systems.
The simplest model of CIM has MES as the middle
ground between ERP systems and individual
machine and automation controls

4. 4
Conceptual Overview
Relationship
Management
Enterprise
Resource
Planning
Manufacturing Execution
Systems
Process
Control
Asset
Optimisation
Customer / Vendor / Employee
Production
Planning &
Scheduling
Robotics
Motors &
Drives
Sensors
& Meters
Power
Electronics
Enterprise
Management
Factory
Management
Automation
and Control
Process
Measurement,
Actuation,
Energy
Distribution
Enterprise
Asset
Management
Real-Time
Systems
Transaction
Systems
Transformers
Switchgear

5. 5
Business Systems

6. 6
Computer Integrated Manufacturing

7. 7
Relationship -ERP & MES
Corporate
Plant
MRP II/
ERP
MES
PLC
Robots/
AGV
DCS
production planning,
scheduling
recipes
process setpoints
operating instructions
reporting or
batch,
production run
completion
,
Planning
lWhen/What to make
lPlanned/standard lead times/
yields/wastes/costs
Execution
lProduction management/tracking
-WIP, equipment, operators
lProduction scheduling
lQuality control/SQC
lCosting
lMaintenance
lManagement functions -
Communications, reporting
Control
lLadder logic
lContinuous feedback
lPID
lAdvanced control
actual process conditons
completion of process steps
and operations, performance of
equipment and raw material &
operator actions

8. 8
Data Flow –ERP & MES
MESA International-White Paper
MPRII/ERP
Forecasting
Costing
Production Planning
Product Definition
Process Definition
SOP
Human Resources
Inventory Management
Purchasing
Distribution
MES
Resource Alloc./Status
Operations Scheduling
Production Dispatching
Document Control
Data Collection/Acq.
Labor Management
WIP Status/Traceability
Quality Management
Performance Analysis
Process Management
Product Tracking
and Genealogy
Maintenance
Management
Monitoring & Sensing
Process
Equipment
Environment
Labor
Material
Control
Machine Control
Regulatory Control
Realtime QC
Advanced Process Controls
Operations
Process Sequencing
Machine & Process Instructions
Labor Instructions
Human Machine Interfacing
Safety
Maintenance
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 Information
Scrap/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
Requirements
Operator 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/Alarms
Data Collected from Monitoring
Functions: Process, Equipment,
Environment, Labor, Material, Product
Parameters
Focus:
Customer
Decision Location:
Office
Focus:
Product
Decision Location:
Factory
Focus:
Process
Decision Location:
Shop Floor/Plant Floor
Planning Execution Control

9. 9
Why MES?
MES have evolved to fill the
communication gap between the
manufacturing planning system (MRP,
ERP, etc.) and the control systems to run
equipment 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

10. 10
Business Drivers
Standard processes to enable
benchmarking and best practices
Seamless Integration
Resource Utilisation
Consistent Documentation
Visibility of data globally
Accurate and consistent measurement
and reporting

11. 11
Benefits
Increases Operational Excellence
Improves Asset Utilisation and the Management of
Assets
Benefits as listed by Manufacturing Enterprise
Solutions 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

12. 12
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

13. 13
ISA 95
ISA = Instrumentation, Systems, and
Automation Society (ISA) Standard
Standard that defines how to link
Enterprise systems with MES layer.
–The MES Functionality
–The Data base schema at the MES Level
–The Messages between the Enterprise system
and MES

14. 14
Business Functions
Demand
Planning
Supply 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

15. 15
MES Functionality
Dispatching and Production
–Manages the flow of production in the form of jobs, orders,
batches, lots and work orders by dispatching production to
specific equipment and personnel.
–Includes information that is presented in the sequence in which
the work needs to be done.
Quality Management
–Provides real-time measurements collected form manufacturing
to assure proper product quality control and to identify problems
requiring 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

16. 16
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 handle
process 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 production
information 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

17. 17
MES Functionality (Contd.)
Performance Analysis
–Provides real-time reporting of actual manufacturing operations
results along with comparisons to past history and expected
results.
–Performance results include resource utilisation, resource
availability, 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.

18. 18
MES Functionality (Contd.)
Labour Management
–Provides status of personnel.
–Includes time and attendance, certification tracking, as
well as preparation work as basis for activity–based
costing.
–May interact with resource allocation for optimal
assignments.
Maintenance Management
–Functionality for maintaining equipment and tools.
–Ensures equipment and tools availability for
manufacturing.
–May also include scheduling for periodic or preventive
maintenance.
–Maintains history of past events to aid in diagnosing
problems.

19. 19
System / Response Time
Planning
Level
Execution
Level
Control
Level
Supervisory
Level
ms seconds hours days weeks month years
ERP
(Enterprise Resource Planning)
DCS
(Distributed Control
System)
MES
(Manufacturing Execution System)
PLC
(Programmable Logic
Controller)
SCADA
(Supervisory Control and Data
Acquisition)

20. 20
MES -Vendors
ABB 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)

21. 21
Good Luck
http://www.linkedin.com/in/anandsubramaniam