closing the gap with mes - dau.dk...closing the gap with mes by leif poulsen, senior specialist,...

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

3

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

7

1. Priority 2. Priority 3. PriorityTypical Priorities:

MES Integration Alternatives (Example)

8

9

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

1 2 3 4 5

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)


(MES)


(MES)

ProductionExecution

(MES)

ProductionExecution

(MES)

ProcessSupervision& Control

(MES/PCS)


(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)


Engineering(CMMS)

Building &EnvironmentManagement

(BMS)


(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



ProductionExecution

ProductionExecution



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


Engineering


Engineering



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

14

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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