mes from the ground up

1

MES: A View from the Shop Floor

Edward Brown

What is MES?

The Big Bang Theory

Evolution not Revolution

Charting a Course

World Peace

MES from the Ground Up

Laying the Foundation

Build the Pyramids

Conclusion

2

What is MES?

The Big Bang Theory


World Peace

Charting a Course


Build the Pyramids

Topics

What is MES?

The Big Bang Theory


Charting a Course

World Peace



Build the Pyramids

Conclusion

3

ISA-95 Manufacturing Operations Model

ISA-95 part 3 defines MES/MOM capabilities

INVENTORYOPERATIONSMANAGEMENT

INVENTORYOPERATIONSMANAGEMENT

MAINTENANCEOPERATIONSMANAGEMENT

PRODUCTIONOPERATIONSMANAGEMENT

QUALITYOPERATIONSMANAGEMENT

Procurement(5.0)

ProductionScheduling

(2.0)

Material andEnergy Control

(4.0)

ProductInventory Control

(7.0)

Product CostAccounting

(8.0)

QualityAssurance

(6.0)

ResearchDevelopment

and Engineering

ProductShipping Admin

(9.0)

OrderProcessing

(1.0)

Marketing& Sales

ProductionControl

(3.0)

MaintenanceManagement

(10.0)

What is MES?

What is MES?

The Big Bang Theory


Charting a Course

World Peace



Build the Pyramids

Conclusion

Trickle Down Theory

DefinedIn S95

Business Logistics SystemsPlant Production Scheduling

and Operational Management

Level 4

Manufacturing Control SystemsArea Supervision, Production

Scheduling, Reliability Assurance

Level 3

BatchControlSystems

DiscreteControlSystems

ContinuousControlSystems

Levels2,1,0 Defined

In S88

What is MES?

What is MES?

The Big Bang Theory


Charting a Course

World Peace



Build the Pyramids

Conclusion

Information is the CurrencyWhat is MES?

What is MES?

The Big Bang Theory


Charting a Course

World Peace



Build the Pyramids

Conclusion

Product Definition Information

Maintenance Information

Scheduling CapabilityInformation

Production CapabilityInformation

Scheduling information on production equipment, including information notrelated to production capability

Maintenance information on production equipment, including information not related to the production capability

Preventive/Predictive Maintenance Information

Scheduled Production equipment outages

Production equipment status

Production Capacity (Including equipment organization and product flows)

Production capability and capacity definition, is specific to an area, process cell, production unit, assembly line.

What is MES?

What is MES?

The Big Bang Theory


Charting a Course

World Peace



Build the Pyramids

Conclusion

Production Capability Information

Maintenance

Information

SchedulingCapability

Information

ProductionCapability

Information

Scheduling information on production equipment, including information not related to production capability

Maintenance information on production equipment, including information not related to the production capability

Preventive/Predictive Maintenance Information

Scheduled Production equipment outages

Production equipment status

Production Capacity (Including equipment organization and product flows)

Production capability and capacity definition, is specific to an area, process cell, production unit, assembly line.

What is MES?

What is MES?

The Big Bang Theory


Charting a Course

World Peace



Build the Pyramids

Conclusion

Production Information

InventoryInformation

SchedulingInformation

ProductionInformation

Scheduling information on production

Information on all inventoriedmaterial and equipment.

Production Schedule andProduction Performance

Production Line Item Information

Production information, is specific to an area, process cell, production unit, assembly line. (Batch Journal, log, …)

Production Material Information

What is MES?

What is MES?

The Big Bang Theory


Charting a Course

World Peace



Build the Pyramids

Conclusion

9

In the beginning there was nothing, and it exploded.

- Terry Pratchett

MES Implemented as a Large Footprint Application

Follows ERP implementation model (all functionality at once)

Can perform most or all functions in the MOM

Capability to pass information across all areas of the MOM model from/to ERP and PCS levels

Tightly integrated functional modules across manufacturing

Technology centric, business processes adjust to application procedures

The MES “Big Bang” Theory

The Big BangTheory

What is MES?

The Big Bang Theory


Charting a Course

World Peace



Build the Pyramids

Conclusion

10

Significant Capital Investment Application Packages from 250K single site – 10M

enterprise

Significant Resource Investment Requires dedicated project teams and subject matter

experts

Duration of project can last from 6 months to 3 years

Significant IT, Management, Operator Training

Significant IT support for application life

Sticker Shock

The Big BangTheory

What is MES?

The Big Bang Theory


Charting a Course

World Peace



Build the Pyramids

Conclusion

11

Significant Change Management Process Companies overestimate the understanding of their own

processes

Companies underestimate the impact of implementing new manufacturing and business processes

Resistance to change is often significant without comprehensive representation in designing process change

Difficult to predict full impact of change from one area to another

Change or Revolution?

The Big BangTheory

What is MES?

The Big Bang Theory


Charting a Course

World Peace



Build the Pyramids

Conclusion

12

Long and Complicated Implementations Requirements, analysis, and design period can consume

significant portion of projected effort

Customizations can consume more than half of required project effort

External system interfaces can require significant effort of those systems IT personnel

A Long Hard Road

The Big BangTheory

What is MES?

The Big Bang Theory


Charting a Course

World Peace



Build the Pyramids

Conclusion

13

Determining Return on Investment can be difficult

Good and Bad effects of integrated functions can make it difficult to determine specifics

Quality of requirements and design usually have bigger impact on ROI than the function itself.

Wrong low hanging fruit – Initial assumption of a high ROI function may be misguided

It Shouldn’t Be a Hedge Fund

The Big BangTheory

What is MES?

The Big Bang Theory


Charting a Course

World Peace



Build the Pyramids

Conclusion

14

If one is master of one thing and understands one thing well, one has at the same time, insight into and understanding of many things.

- Vincent van Gogh

MES Implemented in Incremental Steps

Select one or few MOM capabilities to implement

Add MOM capabilities over time

Exchanges information with implemented features from/to ERP and PCS levels as required

Loosely coupled functional modules across manufacturing with the ability to leave legacy systems in place

Process centric approach using appropriate technology as needed through combination of customization and extension of existing systems and incorporating new technologies/applications

The Evolutionary Approach


What is MES?

The Big Bang Theory


Charting a Course

World Peace



Build the Pyramids

Conclusion

15

Reasonable Capital Investment Pay for what you use – Smaller Technology Purchases

Supporting Infrastructure matched to technology – some increments may not require it

Reasonable Resource Investment Smaller Project teams and fewer subject matter experts

specific to capability and for shorter duration

Duration of project reduced, typically 3-6 months

Reduced IT, Management, Operator Training

Reduced IT support for new application(s)

Efficiency Drives Evolution


What is MES?

The Big Bang Theory


Charting a Course

World Peace



Build the Pyramids

Conclusion

16

Simplified Change Management Process Concentrate on understanding one or a few processes

well

More time to understand the impact of implementing a new manufacturing and business process

Resistance to change can be reduced by including selective representation in designing process change

Easier to predict full impact of change from one area to another

A Welcome Change


What is MES?

The Big Bang Theory


Charting a Course

World Peace



Build the Pyramids

Conclusion

17

Shorter and Simplified Implementations

Requirements, analysis, and design period scaled to MOM capability being implemented

Customizations limited to single/few capabilities

External system interfaces may not be required for some capabilities and are limited for those that are

Quick AND Easy?


What is MES?

The Big Bang Theory


Charting a Course

World Peace



Build the Pyramids

Conclusion

18

Easier to Determine Return on Investment

Good and Bad effects of implemented capability are readily apparent

Quality of requirements and design are usually improved because scope is smaller and easier to understand

Low Hanging Opportunities can be evaluated quickly and expanded or contracted as required

Hard ROI evidence justifies next increment

ROI Clarity


What is MES?

The Big Bang Theory


Charting a Course

World Peace



Build the Pyramids

Conclusion

19

Successful MES Projects are PROCESS Centric

Use the ISA-95 MOM model to determine activities for consideration

Determine the current state of the process thoroughly

Getting MES Processes Right is a TEAM Effort

MES isn’t an IT initiative, it’s a Team initiative

MES SUPPORTS Lean and Six Sigma Initiatives

The Right Representation for the Capability

Capabilities may dictate different SME’s, Operators, IT skills

One Team, One Manufacturing World

World Peace

Finding good players is easy. Getting them to play as a team is another story.

- Casey Stengel

What is MES?

The Big Bang Theory


Charting a Course

World Peace



Build the Pyramids

Conclusion

20

Let our advance worrying become advance thinking and planning.

- Winston Churchill

Creating a Long Term Plan Document Business Goals and Objectives

Build Capabilities Pyramids to Achieve World Class Status

Identification of Low Hanging Opportunities

Collaboration Workshops to Develop Roadmap(s)

A Long Term Roadmap is Essential

Charting a Course

What is MES?

The Big Bang Theory


Charting a Course

World Peace



Build the Pyramids

Conclusion

21

Business Goals and Objectives Initiatives Key Performance Indicators Objectives & Constraints Customer/Supplier Effectiveness

ISA-95 Activity Survey Conduct Surveys for candidate Department(s) Small SME Teams Complete ISA-95 Activity Survey

Determine Shortfalls by Activity Develop As-Is Process Flow Determine List of Shortfalls by Activity Determine Cost of Shortfalls

Create Measurable Objectives

Charting a Course

What is MES?

The Big Bang Theory


Charting a Course

World Peace



Build the Pyramids

Conclusion

Clarify Objectives and Requirements

Charting a Course

What is MES?

The Big Bang Theory


Charting a Course

World Peace



Build the Pyramids

Conclusion

23

Best in Class is represented by companies who support ever increasing capabilities of:

Automation

Conversion of paper processes to electronic

Data capture through equipment and instrumentation

Minimizing Operator Input

Integration

Integrating functional data from operation to operation

Integrating functional data across capabilities

Integrating functional data across business units and plants

Build Capabilities to Reach Best In Class

Charting a Course

What is MES?

The Big Bang Theory


Charting a Course

World Peace



Build the Pyramids

Conclusion

24

Develop capabilities that reflect Business Goals and Objectives

Build Capability Pyramids

Integration

Automation

Foundation

Goal

Best In Class


What is MES?

The Big Bang Theory


Charting a Course

World Peace



Build the Pyramids

Conclusion

25

Select Candidate Capabilities from Goals & Objectives

Map MOM Activities to Capabilities

Determine Automation Requirements

Determine Low Hanging Opportunities


A successful man is one who can lay a firm foundation with the bricks others have thrown at him.

- David Brinkley

What is MES?

The Big Bang Theory


Charting a Course

World Peace



Build the Pyramids

Conclusion

26

Scenario: Operators at the Acme Drug Company add to the Batch Record at Compounding by physically attaching a paper trend chart for environmental conditions. On average, three incidents per Quarter occur where the incorrect chart data was associated with a Batch. Of those incident batches, one batch in three cannot be resolved and is lost.

Costs: Annual time and material4 quarters * 3 incidents = $15K-$50K

4 quarters * 1 batch/quarter = $1M - $5M

Opportunity $1M – $6M

A Genealogy MOM Capability Appears to be a Viable Candidate Project.

Identifying the Target


What is MES?

The Big Bang Theory


Charting a Course

World Peace



Build the Pyramids

Conclusion

27

Map MOM Activities to Capabilities


What is MES?

The Big Bang Theory


Charting a Course

World Peace



Build the Pyramids

Conclusion

28

Hold Workshop(s) for Selected Capability

Build the Pyramids

No one wants advice, only collaboration

- John Steinbeck

What is MES?

The Big Bang Theory


Charting a Course

World Peace



Build the Pyramids

Conclusion

Process Maps are the Foundation

Build the Pyramids

What is MES?

The Big Bang Theory


Charting a Course

World Peace



Build the Pyramids

Conclusion

Determine Automation Data Requirements

Build the Pyramids

What is MES?

The Big Bang Theory


Charting a Course

World Peace



Build the Pyramids

Conclusion

31

Quality Data Collection & Tracking

Collect and Associate Quality Test results with Batch

Lot Management

Record Consumption of Raw Material Lots

Material Tracking

Record movement of materials from location to location

Production Execution

Record Environmental Data to Historian

Record CIP/SIP Data to Historian

Record and Associate production data with Batch Record

Genealogy Automated Data Collection

Build the Pyramids

What is MES?

The Big Bang Theory


Charting a Course

World Peace



Build the Pyramids

Conclusion

32

Using or expanding the Automation functions you already have is a smart way to achieve MES functionality

What’s in the Backyard?

Build the Pyramids

What is MES?

The Big Bang Theory


Charting a Course

World Peace



Build the Pyramids

Conclusion

A MES Repository Aggregates & Associates

Build the Pyramids

What is MES?

The Big Bang Theory


Charting a Course

World Peace



Build the Pyramids

Conclusion

34

Provide MES Repository Structure for Capability Associations

Allow individual MOM Capabilities to Utilize Structures and Associations as needed

Add Capabilities by Exposing Additional MES Associations and Structures

$60K-$300K Typical Installed Cost

Extendable MES Requirements

Build the Pyramids

What is MES?

The Big Bang Theory


Charting a Course

World Peace



Build the Pyramids

Conclusion

Map Functions to Technologies

Build the Pyramids

What is MES?

The Big Bang Theory


Charting a Course

World Peace



Build the Pyramids

Conclusion

36

Justify the Necessity

Build the Pyramids

What is MES?

The Big Bang Theory


Charting a Course

World Peace



Build the Pyramids

Conclusion

37

Extend Legacy Systems where appropriate

Develop Automation capability where necessary

Implement limited MES functionality with compartmentalized capabilities

Establish and Monitor Process Improvement Metrics

Measure and Document ROI

Use ROI to Justify Next Brick

Implement and Evaluate

Build the Pyramids

Plans are only good intentions unless they immediately degenerate into hard work.

- Peter Drucker

What is MES?

The Big Bang Theory


Charting a Course

World Peace



Build the Pyramids

Conclusion

Build on Capabilities

Build the Pyramids

What is MES?

The Big Bang Theory


Charting a Course

World Peace



Build the Pyramids

Conclusion

39

Growing MES Provides a Reasonable Alternative

Reasonable Capital Investment

Reasonable Resource Investment

Simplified Change Management Process

Shorter and Simplified Implementations

Easier to Determine Return on Investment

Process is More Important than Technology

Determine Ripe Opportunities

Include All Stakeholders in Collaboration Workshops

Conclusions

Conclusion

What is MES?

The Big Bang Theory


Charting a Course

World Peace



Build the Pyramids

Conclusion

40

Capability Pyramids Provide Context

Clearly Defines Goals and Necessary Elements for Growth

Automation can Provide MES capabilities

Current Automation Data Aggregated to MES DB

Extending Automation Capability can be more Efficient

Measuring Performance Justifies Next Steps

KPI’s Show Operational Improvements for Change Management

ROI Measurements provides Business Case for additional capability

Conclusions

Conclusion

41

Questions?

Web Site: www.AvidSolutionsInc.com

Contact Information:

Ed Brown – 919.606.9592

Shane Bernard– 336.409.9894

mes from the ground up

Business

production unit

exchanges information

significant effort

significant capital

new manufacturing

big bangtheory11

process cell

impact of change