IntegraMES—Manufacturing Execution System

In today’s challenging economy, manufacturers are under constant pressure to surpass customer expectations. Reducing time-to-market is something you think about daily. At the same time, you have to

reduce costs, make your workforce more efficient, deliver quality products and ensure you meet governmental and regulatory compliance. Essentially, you need total and complete control over your operations. You need a unified, manufacturing-centric, digital platform that delivers the full set of core manufacturing execution system (MES) functions.

IntegraMES provides the infrastructure to achieve collaboration with multi-faceted, complex, cross-facility MES business units and processes. Timely information collection and knowledge sharing ensures integral information is delivered to the right resource at the right time avoiding costly delays or downtime. Complete system integration unites the entire manufacturing chain of operations from planning and scheduling through to logistics’ fulfillment.

IntegraMES brings tangible visibility into factory performance through real-time understanding of throughput expenses, which helps reduce costs. Efficiencies throughout the system are tracked, aggregated, and reported to provide business intelligence analysis on your big data that supports lean manufacturing, continuous improvement, and predictive, fact-based decision making. Quality management is linked throughout the system to ensure product and process performance along with system data integrity, consistency, and accuracy.

IN PRODUCING THE WORLD’S

MOST ADVANCED AIRCRAFT, IT

IS ESSENTIAL TO RECORD AND

VALIDATE DETAILS OF ALL WORK

PERFORMED, AS IT OCCURS.

WE NEED TO DO THIS WITHOUT

CREATING ADDITIONAL OVERHEAD.

THE OPEN STANDARD SOLUTION

FROM EPIC DATA BRINGS

OUR VARIOUS STANDALONE

SYSTEMS UNDER A UNIFIED

AND MUCH MORE EFFICIENT

COMMUNICATIONS UMBRELLA.

— Lockheed Martin

PREVIOUSLY, OUR INVENTORY

WAS REPORTED MANUALLY, WITH

THE ACCOMPANYING ERRORS

THAT OCCUR WHEN YOU HAVE

1.5 MILLION TRANSACTIONS

PER YEAR. NOW, ALL INVENTORY

CHANGES ARE RECORDED

AUTOMATICALLY IN REAL TIME AS

THE STAFF PERFORMS FUNCTIONS

OF PRODUCING PARTS. THE EPIC

DATA SYSTEM HAS HELPED THE

COMPANY TO REDUCE COSTS

AND REASSIGN STAFF TO MORE

VALUABLE TASKS.

— Listowel

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“

“

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MES for all manufacturingIntegraMES is designed for various manufacturing operational strategies and industry-standard functional processes. The suite of modular applications can support a range of manufacturing environments and the operational strategies needed to meet specific manufactured product requirements.

IntegraMES supports industry-standard manufacturing operational strategies:

• Process • Discrete • Repetitive • Synchronous • Cluster

Reliable process control generates predictable results. Instant awareness delivers the agility to respond rapidly. IntegraMES— visibility driving perfection.

Complete MES solution — industry leading functionality supporting best practicesThe IntegraMES design is modeled following industry standards: Manufacturing Enterprise Solutions Association (MESA) and the International Standards Association (ISA-95).

IntegraMES covers all MES functional areas:

• Operations/Detailed Scheduling • Dispatching Production Units • Resource Allocation • Process Management • Quality Management • Labor Management• Maintenance • Product Tracking & Genealogy • Data Collection• Performance Analysis • Document Control

Dispatching Production Units Direct Production Units’ Workflow

Direct, monitor, and balance production runs through buffer management and system controls that provide as-built data to react to actual workflow:

• jobs

• sales orders

• production orders

• work orders

• lots/serial runs

• automated and batch routing

Labor/User ManagementLabor Tracking and User Management

Control and regulate all personnel time and attendance, user access and tracking with flexible configuration options to match human resource processes:

• group classes

• user permissions’ tracking

• qualification & certifications

• operator IDs

• T&A reporting

Operations/Detailed SchedulingManage Production Flow Direct scheduling, control and regulate all units associated with executing production and operations’ workflows:

• current/real time operation and work center details

• production unit work orders from an enterprise or planning systems

• routines for work subsets (jobs, batches, lots, etc.), presented at each work center in the most efficient sequence

• operations’ schedules optimization for real-time events: yield deviation, split batches, unplanned downtime, and operator decision

• work order initiation for plant operations (inventory, maintenance, quality, production)

• real-time data dynamically pushed for true visibility to plant floor personnel so rescheduling is based on actual production

• Sequential • Loose-coupled • Batch-to-discrete • Continuous process

• operation sequence in real-time as events occur on the factory floor

• alter factory-floor schedules and production plans

• modify material preparation and handling and process operations— rework, recovery, and salvage.

• worker activities

• certification tracking

• labor skills’ validation

• indirect activities’ tracking— material or tooling preparation

Process ManagementManage As-planned Processes

Identify and prioritize planning for increased effectiveness and efficiency throughout extensive and complex processes and operations:

• definitions

• routings

• data collection and monitoring

• process control for individual or interrelated operations

• quality, yield, and throughput data

• decision support for instructional and historical information

• recipe definition/program files at the operation point

• condition notification (alerts, alarms, warnings, events)

• business rules configured to available captured data.

• OPC interoperability protocols

• automated attribute monitoring — values/range data stored locally or controlled electronic documents

• operations and routing revised to changing needs

Configured to Business Rules Deploy, configure, and enforce manufacturing processes and assets according to organizational practices and operational strategies:

• redirect resources to adjust processing for improved results

• increased material flow into a process

• feed-forward adjustments to change process parameters downstream

• feed-back to change process parameters upstream to achieve a higher yield/improved quality

• define the next operation required

• provide routing alternatives to eradicate non-conformance sub-routings or rework operations

• execute binning/kitting for distinct operations

• split or merge production units to balance lines

Quality ManagementSystematic Quality Control

Direct, regulate, and control quality management processes and activities for all areas of manufacturing:

• planning

• quality control

• quality assurance

• process control — SPC analysis

• negative trends

• business rule/specification non-conformance

• online and offline data stores

• data linked to product unit tracking and genealogy

• documentation revisions/resource history

• defects and non-conformance production irregularities

• quality problems top contributors (Pareto)

• PDM

• ERP

• SCM

• PLCM

• LIMS

• OPC

Condition Monitoring Control extensive, production condition monitoring and production alerts using automated, flexibly-configured, complex messaging triggers:

• alerts, alarms, warnings, events

• SPC violations

• negative trends

• abnormal parameters

• irregular or non-conformance data

• material quality monitoring, validation, and testing

Maintenance ManagementMaintenance, Repair, and Overhaul (MRO) Oversee, monitor, track, and direct entire, plant- and organization-wide Maintenance, Repair, and Overhaul (MRO) activities:

• equipment and tooling availability • scheduling periodic or preventive maintenance • immediate problems/breakdowns notification • diagnosing current and future issues • OPC for CNC-managed

Resource Allocation/StatusManage Non-Labor AssetsOptimize management of all non-labor assets by defining and modifying capabilities and capacity for an ever-changing environment:

• equipment • support documentation• tooling and fixtures • vessels• current state • volume previously produced• resource preparation/setup, current & historical

• maintenance, repair, overhaul (MRO)

Copyright ® 2012, Epic Data International Inc., All rights reserved. All company and product names are trademarks or registered trademarks of their respective holders. The information in this document is subject to change without notice.

ABOUT EPIC DATAEpic Data is a trusted provider of Manufacturing Execution Systems (MES) and Warehouse Management Solutions to the world’s most progressive discrete manufacturers. We focus on knowing what is important to our customers and delivering solutions that last, resulting in relationships that have spanned over three decades.

Head Office: (+1) 604.273.9146UK Office: +44 1635 521140

China Office: +86 (21) 6040-6566Email: info@epicdata.com

Web: www.epicdata.com

Document ControlIntegrated Documentation Support Control and deliver extensive information, resource work instructions, and change notices to production units when and where the data is needed:

• control current, historic, and future product-related documentation

• execute corrective action procedures, engineering and change processes

• distribute shift-to-shift communications through electronic job travelers

• edit “as planned” information and specification histories

• control environmental, health, and safety regulations

• manage data for product life cycle management (PLCM) and product genealogy

• deliver production unit operations: work instructions, recipes, drawings, standard operating procedures (SOPs), part programs, batch records, engineering change notices

Product Tracking and GenealogyProduct Tracking and Genealogy Access real-time, ‘as-planned and as built’ information to understand the entire genealogy for each product or sub-assembly produced:

• setup activities

• operation start and end time

• data collection

• process revisions

• operator ID

• reference data

• materials consumed

• unplanned work splitting

• non-conformance holds

Data Collection/AcquisitionComplete Access to All DataCollect, access and deliver all manufacturing functional information including operations, production, and parametric data:

• equipment

• materials

• labor

• operations

• processes

• integrated systems

• statistical process control

• actual cost

• dispatch execution

Data collected from diverse devise types (e.g., input screens, PCs, hand-held devices,

smart phones, barcodes, radio frequency ID (RFID) tags, etc.).

• forward/backward process control

• trend analysis

• resource conditions

• cycle count and utilization

• database/transaction health

• scrap/reworks/defects/ non-conformance

• bin information

• corrective actions

• OPC functions for CNC-managed equipment

• scrapping/reworks

• non-standard routing & decisions made at operation

• key timestamps

• staff assignments

• components

• supplier materials

• lot/serial number

• current production conditions

• alarms

Performance AnalysisVisibility – past – present – futureMake fact-based decisions through dynamically updated, real-time and historical analytical data that is mined, aggregated, and delivered to the right resource at the right time:

• personalized dashboards

• trend monitoring

• predictive analysis

• condition monitoring (alarms, warning, events)

• metrics for the entire production environment

• business guiding metrics

• pushed data for core and related manufacturing functions

• production abnormalities

• comparisons by period, plan, shift, supplier or product

• business metrics outside normal conditions

• production completions per unit

• expected cycle time vs. actual cycle time

• average non-conformance to specification or process

• equipment failures

• material shortages

• WIP build-up

• certification tracking

• SPC & OPC activities