Closing the Gap with MESBy Leif Poulsen, Senior Specialist, PhD, Automation & IT
NNE Pharmaplan, Nybrovej 80, DK-2820 Gentofte, DenmarkPhone +45 4442 1701, E-mail [email protected]
MES definition according APICS
• A Manufacturing Execution System is a factory floor information and communication system with several functional capabilities.
• It interfaces with and complements accounting-oriented, resource planning systems.
• It includes functions such as resource allocation and status, operation detailed scheduling, dispatching production units, document control, data collection and acquisition, labor management, qualitymanagement, process management, maintenance management, product trackingand genealogy and performance analysis.
• It can provide feedback from the factory floor on a real time basis.
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MES used to Close the Gap
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ERP Level
Supply Chain
MES as theMissing Link
PCS Level
Mfg. Chain
Supplier
Customer
Raw Material
Finished Goods
Slide no 4
MES Domain (Manufacturing Operation Management) according ISA
MES Main Functions• Production Definition Management (bill of materials,
recipes, SOP’s etc.)• Production Resource management (personnel,
equipment, materials etc.)• Production Scheduling (generation, release and
maintenance of detailed plans)• Production Dispatching (generation and distribution of
control information)• Production Execution Management (start, coordination
and guidance during execution)• Production Data Collection (collection of process data,
alarms, events etc.)• Production Performance Analysis (analysis and display
of process data, trends etc.)• Production Tracking (tracking of resources like
operators, equipment and materials)
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Production Operations Management
Production Execution
Management
Production Data
Collection
Production Tracking
Production Performance
Analysis
ProductionScheduling
ProductionDefinition
Management
ProductionResource
Management
Production Dispatching
MES Functions Example (PAS-X)
Electronic Batch Record Completed Batch RecordMaster Batch RecordBill of MaterialProcess DescriptionReview & ApprovalVersion Number
Production ScheduleProcess Order NumberBatch NumbersRight Sequence & Right First Time
Process Parameters/TrendsCritical Alarms/EventsExceptions/DeviationsReview by ExceptionElectronic Signatures
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MES Main Interfaces
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SAP
MES
MaterialMovement
MaterialMovement
ProcessOrderComplete
ProcessOrder
MaterialConsume
MaterialProduce
BatchQAStatus
ProcessStatus
MasterDataUpdate
1 2
3
4
5 6 7 8
9BatchQAStatus
10
PCS
MasterData
Update
1
Batch/Recipe
Info
2Equipment
Status
3
Batch/ Operation
Start
4Batch/
OperationStatus
5
Batch Data
6
Alarm/ Events
8 9
Batch/Operation
Completion
ContinuousData
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1. Priority 2. Priority 3. PriorityTypical Priorities:
MES Integration Alternatives (Example)
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MES Product Market
POMS from Honeywell POMS Corp., USAPMX from Rockwell/ProPack, GermanyPAS-X from Werum, GermanyXFP from Siemens/Elan, FranceSyncade from Emerson/DMI, USAFactoryTalk Pharma Suite/Rockwell, USA
iBatch from GE-Fanuc, USAInBatch from WonderWare/Invensys, USA System800xA from ABB, USADeltaV from Emerson, USAPCS7 from Siemens, Germany
BaanERP from Baan, The NetherlandsPP-PI from SAP, Germany ERP Suppliers
MES Suppliers
DCS/SCADASuppliers
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MES Implementation Model
• Establishing a common vision
• Definition of overall scope
• Selection of implementation approach
• Assessment of cost & benefits
• Identification & assessment of risks
• Analysis of business processes & workflows
• Specification or requirements
• Classification of requirements
• Market Scanning based on Request for Information (RFI)
• Request for Proposals (RFP)
• Conference Room Pilot (CRP)
• Reference Visits in Peer Companies
• Final Selection of Product & Partner
• Project management
• Development of MES Core
• Configuration of MES application
• Quality Assurance• SOP Development• Training
• Change Control• Configuration Management
• Access Control & Security
• Backup & Recovery of Software & Data
• Record Retention, Archive & Retrieval
• Performance Monitoring & Periodic Review
• Risk Assessment & Contingency Planning
Business Analysis & Strategic Planning
Workflow Analysis & Requirement Specification
Product & Partner Selection
Implemen-tation & Validation
Operation & Support
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Experience: +15 full MES solutions, +25 partial MES solutions, +5 MES platforms
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Business Analysis & Strategic Planning• Establishing a common vision• Definition of overall scope• Selection of implementation approach• Assessment of cost & benefits• Identification & assessment of risks
Business Data
Applications & Interfaces
IT Infrastructure
Enabling Services
Business Objectives
Business Processes
Business Data
Applications & Interfaces
IT Infrastructure
Enabling Services
Business Objectives
Business Processes
S95
MRPPlanning
(SAP)
MRPPlanning
(SAP)
Finance,Accounting
& IT(SAP)
Finance,Accounting
& IT(SAP)
ProductionScheduling
(MES)
ProductionScheduling
(MES)
ProductionExecution
(MES)
ProductionExecution
(MES)
ProcessSupervision& Control
(MES/PCS)
ProcessSupervision& Control
(MES/PCS)
Research &Development
(N/A)
Research &Development
(N/A)
QualityAssurance
(QMS)
QualityAssurance
(QMS)
QualityControl(LIMS)
QualityControl(LIMS)
InventoryManagement(SAP/MES)
InventoryManagement(SAP/MES)
HumanResource
Management(SAP)
HumanResource
Management(SAP)
MaterialManagement
(MES)
MaterialManagement
(MES)
Energy & Utility
Management(BMS)
Energy & Utility
Management(BMS)
Purchasing&
Supply(SAP
Purchasing&
Supply(SAP
EquipmentMaintenance &
Engineering(CMMS)
EquipmentMaintenance &
Engineering(CMMS)
Building &EnvironmentManagement
(BMS)
Building &EnvironmentManagement
(BMS)
Marketing,Sales &
Distribution(SAP
Marketing,Sales &
Distribution(SAP
ProductionSpecification(SAP/MES)
ProductionSpecification(SAP/MES)
ProductionOptimisationProduction
Optimisation
ProductionReporting
(SAP/MES)
ProductionReporting
(SAP/MES)
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Workflow Analysis & Requirement Specification• Analysis of business processes & workflows
(S95 based, Lean Thinking)• Specification of requirements (S95 based)• Classification of requirements (C/Q)
MRPPlanning
MRPPlanning
Finance,Accounting
& IT
Finance,Accounting
& IT
ProductionScheduling
ProductionScheduling
ProductionExecution
ProductionExecution
ProcessSupervision& Control
ProcessSupervision& Control
Research &DevelopmentResearch &
Development
QualityAssuranceQuality
Assurance
QualityControl
QualityControl
InventoryManagementInventory
Management
HumanResource
Management
HumanResource
Management
MaterialManagement
MaterialManagement
Energy & Utility
Management
Energy & Utility
Management
Purchasing&
Supply
Purchasing&
Supply
EquipmentMaintenance &
Engineering
EquipmentMaintenance &
Engineering
Building &EnvironmentManagement
Building &EnvironmentManagement
Marketing,Sales &
Distribution
Marketing,Sales &
Distribution
ProductionSpecificationProduction
Specification
ProductionOptimisationProduction
Optimisation
ProductionReporting
ProductionReporting
MES Requirements Specification
Functional Requirements
Data Requirements
Platform requirements
Interface Requirements
Infrastructure Requirements
Support Requirements
Other Requirements
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Product & Partner Selection• Market Scanning based on Request for Information (RFI)• Request for Proposals (RFP)• Conference Room Pilot (CRP)• Reference Visits in Peer Companies• Final Selection of Product & Partner
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Implementation & Validation• Project/Change Management• Functional Specification & Prototyping• Development/Customisation of Core• Configuration/Parameterisation of Cluster• Installation, Test & Validation of Cluster• SOP Development & Training
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Operation & Support• Change Control• Configuration Management• Access Control & Security• Backup & Recovery of Software & Data• Record Retention, Archive & Retrieval• Performance Monitoring & Periodic Review• Risk Assessment & Contingency Planning
MES Challenges & Recommendations• MES systems are complex systems (strong scope
management to keep budgets and time schedules)• MES systems go across organisational boundaries and
involves many stake holders (organisational change management is very important)
• MES systems interact with many processes (harmonized/ standardised is important)
• MES systems require access to a lot of data (important to clearly define who owns, creates and maintains data)
• MES software platforms are often design for certain processes (select a platform which can cope with your requirements)
• MES systems require a good infrastructure (get support from internal/external IT partners)
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MES Benefits• Good data basis for documentation of production• Good data basis for optimisation of processes• Less human errors due automated data capture
through barcode scanners and automated data transfer through electronic interfaces
• Faster throughput time, better utilisation of resources and less level of material inventories due to optimisation of detailed schedules
• Better overview and ability to catch deviations and errors in due time
• Better security around access to critical information• Improved compliance with regulatory requirements
through electronic work flow and dynamic check of specified tolerances.
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MES Related Trends• Better integration and access to data across the
organisation (data transparency)• Slim lining of heavy paper based procedures
(paperless manufacturing)• Optimisations of business and manufacturing
processes (operational excellence)• More user-friendly systems which can provide
overview (early warnings)• Systems that can track products and equipment
(serialisation requirements)• Systems that can exploit recent innovations within
technology (e.g. smart phones/tablets)
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Questions
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