next generation manufacturing application - oracle · next generation manufacturing application ......

Next Generation Manufacturing ApplicationExecute and Manage Shop Floor Functions Efficiently

CONFIDENTIAL: All capabilities and dates are for planning purposes only and may not be used in any contract

SUPPLIERS

CUSTOMERS

CORPORATE HQ (with EnterpriseBusiness Apps )

Lack of integration between plant-level Manufacturing Execution Systems (MES) results in fragmented data and poor synchronization

Inadequate coordination causes inflexible make-to-stock production to “product push” requirements

Latent information results in reactive quality management

• Excess Rework• Compliance Problems

• High WIP and Inventory

Limited visibility to work in process (WIP) inhibits responsiveness to “demand pull”

• Incorrect Planning Information

• Missed Promise Dates• Inaccurate Order Status

MES 1 MES 2 MES 3

Operational Challenges

Component Assembly Final Assy

• Dedicated Lines


Shop Floor Mgmt in SMT environment

LOADING MPM CHIP MOUNT OVENSMT PROCESS

PCB Panel

Components 1…N(Top 3x/Bottom 4x)

DateCode

Store

12345

SMTTop

SMTBottom

SMT TrackingData-Collector SMT Component Setup

Batch No.

Soldering Station

Component

BACK-END PROCESSPANEL SEPARATION MI

UniqueSerial No.

TestICT

ICT Station

Final TestFT

FT Station

Test Results

Rework Station

Rework Stations

Panel Level Tracking Unit Level TrackingPanelBoard

SMT Board and Box Built


Detail Shop Floor Tracking

Ethernet/TCPIP

FOLCell

Controller

EOLCell

Controller

MES

RS 232

••Receive lot informationReceive lot information••Manage EOL OperationManage EOL Operation••Lot StatusLot Status••RecipeRecipe••Raw Raw MatMat’’ll••Strip MovementStrip Movement••Defect MappingDefect Mapping••Equipment StatusEquipment Status••Tool kit Tool kit ••SPC/QA InspectionSPC/QA Inspection••Process Data Process Data

StripID Scan Strip ID

Scan Out/Infor Burn-In

Lot Completion StatusTest Results2D/3D Insp ResultUpdate overall defect map

StripID Scan

Solder BallDefect Mapping

MoldDefect Mapping

OverallDefectMap

Sort DefectResult

Lot InforStrip InforRecipe IDTest Program ID

Equipment StatusLot StatusStrip locationProcess parametersDefect Maps Update

Mold PMC Test/LaserMark/Insp

SBP Reflow Cleaning Saw/SortTape

/Reel

StripFromFOL

ToStore

MechanicalFall OutBy Units

Test/Vision InspFall-Out Bin

QA InspScan Out/In

QA InspScan Out/In

StripValidation

To support Strip Level Tracking to improve yield by identifying defect down to unit/panel level


A Need for ChangeLeading Business Trends

• Improved operational efficiencies

• Lean, agile, “paperless” manufacturing

• Standardized plant / shop floor systems

• Increased compliance at a reduced cost

• Real-time shop floor visibility

• Reduced total cost of ownership


How

Delivers

Oracle Solution for Manufacturing


Lot / Serial Genealogy Tracking

Quality MgmtAnalyzeAnalyze AdjustAdjustSampleSample

Project Tracking

Manufacturing Execution

ProductLifecycle Mgmt

Warehousing / Transportation

Service

AssetLifecycle Mgmt

Planning & Scheduling

Flexible, Mixed Mode Manufacturing

Repetitive Flow / Lean

Standard Discrete Lot-Based

ETOATO / CTO

MTS

Shop Floor Sys

PartnerCollaboration and VisibilityContract Mfgrs Suppliers

Manufacturing Intelligence

Visibility from Shop Floor to

Top Floor

S95-Based Data Integration


MES for Discrete ManufacturingControl Demand-Driven Mfg with Integrated Shop Floor Execution

Improve shop floor operator productivity and efficiency

Increase shop floor visibility and reduce compliance risks

Achieve real-time responsiveness for greater agility

Reduce system complexity and integration cost

MESMES

ERPERP

Corp &Mfg Mgmt

Production MgmtProduction Mgmt

System Automation & Control

Shop Floor Control

Oracle MES for Discrete Manufacturing

Improve Shop Floor Operator Productivity and Efficiency

Increase Shop Floor Visibility and Reduce Compliance Risks

Achieve Real-Time Responsiveness for Greater Agility

Reduce System Complexity and Integration Cost

Enables you to…



• Simple, standardized user experience provides all the information needed for operators to execute their work

• Serves as the starting point (“home page”) for any operator

• An integral part of MES for Discrete Manufacturing

Operator WorkstationExecute Efficiently via Timely, Sequence-Based Information

Releases Work Ordersto Shop Floor

Reviews & ResolvesException

Sets up UserRoles and Parameters

Reports Exceptions (if any)

Records Transactions &Completes Work

Notification Sent toSupervisor

PeriodicallyReviewsShop FloorStatus

Administrator Supervisor Operator

Works offDispatchList

Greater productivity

Minimize system interaction time

Reduce usage errors

Lower training costs


Dispatch-Driven Execution Improve Productivity in Alignment with Management Priorities

• Supports a variety of actions and data drilldowns that can be performed quickly on any job operation in a dispatch

• Workstation is sequence-based

• Provides several visual cues that aide operators in performing their work

• Content is highly configurable to improve production efficiencies

Allows Shop Floor Operators to Execute the Work in Management’s Expected Sequence

Allows Shop Floor Operators to Execute the Work in Management’s Expected Sequence


Guided Work InstructionsStandardize Procedures to Reduce Training and Minimize Errors

Work contentWork contentactionsactions

Sequential display Sequential display of instructions (inc. of instructions (inc.

images) enables images) enables companies to go companies to go

““paperlesspaperless”” on the on the shop floor shop floor

• Workstation supports displayof configurable Work Content related to a Job Operation

• Upon completion of a specific job, operators are automatically taken to the detailed work instructions of the next job.

• Work content page provides sequential display of work instructions and simultaneous access to relevant information


Shop Floor Transaction ReportingCapture Activity Details Quickly and Accurately

• Perform multiple activities, all through a single screen• Perform multiple transactions in one pass

Supports severalimprovised transaction reporting methods

Improves operator’s efficiency in reporting shop floor transactions

Eliminates separate, manual transaction recording, saving time to perform value-added manufacturing activities

Perform move transaction

Review & reporttime spent

Enter quality results

Enter component details

Sample Activities


Shop Floor Exception Reporting Raise Visibility for Timely Management Response

Bring attention to events and

occurrences that prevent work progress

Operators Supervisors

Act upon exceptions

Electronicnotification

of exception

Exceptions can be categorically logged against specific exception

types, such as problems with

• Components• Partially finished assemblies• Resources• In-process quality







Enables you to…


SupervisorDashboards

OperatorWorkstations

Greater controlDecrease issue resolution timeMinimize system interaction timeLower training costs

• Presents a summarized view of current shop floor status• Simple, standardized user experience provides all the information

needed to manage jobs and exceptions (issue resolution)• Serves as the starting point (“home page”) for any supervisor

Supervisor Dashboard Obtain Instantaneous Visibility


Supervisor Gantt ChartsSchedule Effectively as Conditions Change

View job View job GanttGantt

View View resource resource

GanttGantt

Load Load summary vs. summary vs. capacity for capacity for

selected selected resourcesresources

Supervisors Access Workbenches Directly through MES for Their

Scheduling Needs

• Graphical schedulingof jobs and resources

• Dispatching based on available capacity and constraints

• Re-balancing loads as conditions change


Role-Based Dashboards and KPIsDeliver Performance Measures by Responsibility

• Pre-built role-specific dashboards, reports, and alerts

• Graphical views- Trend charts- Graphs- Tables

• Embedded best-practice calculations and KPIs

• Analytic workflows to drive actions• Drill-downs into details for

root-cause analysis• Leverages OBIEE+• Configurable and customizable

Are we achieving our costand productivity targets?

What is happening now?What happened last shift?

How is the machine performing?

VP of OperationsPlant Manager

Production ManagerProduction Supervisor

OperatorQA Engineer

- Red-yellow-greenindicators


Example: Production Throughput Analysis Track Production and Identify Potential Bottlenecks

• Track against targets for shift, day, week, or month

• Monitor backlogs by individual equipment

Supervisors,Line Managers

Plant Managers,VP of Manufacturing

• View throughput by product, plant, line,and equipment

• Analyze monthly trends to ensure aggregate performance

Click to Click to view alert view alert

detailsdetails

Visual cues Visual cues quickly indicate quickly indicate

production production status status

Determine Determine equipment statusequipment status

Monitor production Monitor production volumes & throughput from volumes & throughput from anywhere in the enterpriseanywhere in the enterprise


360º View of Equipment PerformanceMaximize Performance of Your Manufacturing Assets

Understand Key Factors that Impact Production Output and Quality

- Production Supervisor- Line Manager- Maintenance Supervisor

For

• Equipment downtime• Mean time to failure• Effective run-time

• Pressure• Temperature• Humidity

• Quantity produced• By hour, shift, week

• Quantity rejected• Quantity scrapped• Defects by reason code

Process Parameters

Availability

Production Quality

Production Output


Production Process Monitoring Proactively Detect and Avoid Potential WIP Problems

• Define your own unique process parameters• Generate control charts• Define control limits and track violations• Trigger workflows based on violations

- Production Operators- Quality Engineers

For

Violation

Monitor TriggerWorkflow

Equipment SPC / SQC Charts Work Queue

03/17/2008

03/14/2008


Extensible Analytical Engine and Dashboarding Tool

Most standard Most standard KPIs availableKPIs availableoutout--ofof--thethe--boxbox

• Accelerate deploymentand adoption

• Easily adapt dashboards and metrics

• Provides a comprehensive Operational Intelligence framework

Easily identify, select, modify, Easily identify, select, modify, and format relevant KPIsand format relevant KPIs

Build a Decision Support System Unique to Your Environment


Serialized Manufacturing ControlsKnow the Source and Placement of Every Part

Boards R’ UsDenver, CO

Acme ChipFab 12

E. StorageAustin, TX

SKD Co.S. Korea

Nippon FabJapan

IrelandManufacturingPartner

Com

posi

tion

Whe

re U

sed

Suppliers

Server(S.No. 512)

Disk B(S.No. 339)

Disk A(S.No. 676)

Disk Array(S.No. 892)

Memory(Lot No. 115)

CPU(S.No. 232)

Storage(S.No. 929)

PCI Board(S.No. 717)

Track and Trace a Customer Shipment, Lot, or Individually-Serialized Product Back to the Original Source


Embedded Electronic Records & Signatures Comply with 21 CFR Part 11 / 820 Requirements

Concept-to-Release Procure-to-Pay Demand-to-Build(e.g. Medical Device History)

Nonconformance Management

Corrective Actions

Inventory Management

Evidence Store w/ Unbreakable

Security

ConfigurableMiddleware

GxP-Critical Events SupportedU

NIFIED

TECHNOLOGY

Supported Business Processes

Reliable Audit Trail Capabilities as

Required by GxP

Validate-able User Controls and

Security Levels

Consistent User Experience Across

All Events

Directly Record and Approve Quality Tracking Transactions







Enables you to…


Foundation: Single Source of TruthMinimize System Response Time While Enabling High Volume Mfg

• Unified information architecture eliminates redundant data

• Common data model eliminates delays from synchronizing multiple application databases

• Eliminates transcription errors

• Supports business growth with record-setting scalability

Manufacturing

Data Model

Manufacturing

Data ModelGra

nula

rity

Enterprise Level- Products- Orders- Plans / Schedules

Plant Level- Dispatch Lists- Work Orders- Mfg Routing

Equipment Level- Availability- Status- Output- Quality- Parameters

Device Level*- I/O Tags- Sensor IDs

*Requires third party partner solution


Production SchedulingExecute Against Demand-Driven Signals

• Advanced Planning (APS) provides demand, planned orders, schedule changes, component substitutes, resources substitutes

• MES automatically converts production plans to shop floor dispatch lists for proper, sequenced execution

Adjust Execution as Forecasts and Plans Change

Planning & Scheduling

Lot / Serial Genealogy Tracking

Quality MgmtAnalyzeAnalyze AdjustAdjustSampleSample

Project Tracking

Manufacturing Execution

Flexible, Mixed Mode Manufacturing

Repetitive Flow / Lean

Standard Discrete Lot-Based

ETOATO / CTO

MTS


• Similar to MES Workstation for Operators

• Supports managerial functions to control shop floor activities

• Provides “one click” access to supervisory functions

- Expedite jobs- Reorder dispatch list based on priority- Report resource usage- Review shop floor transactions- Review Gantts- Review Manufacturing DBI

Supervisor WorkstationRelease Work, Expedite Jobs, and Reorder Dispatch Lists

Supervisors Expedite Jobs andReorder Dispatch Lists in the Workstation


Exceptions Can Be Resolved by Assigning Alternate Resources,

Rescheduling Job Operations, Placing Problematic Jobs

“On Hold”, etc.

• Supervisors can associate an exception with all jobs that may be impacted by the issue

• Drill down to the specific details of the exception and take appropriate action for resolution depending upon the type of exception logged

Exceptions can be Exceptions can be applied to Impacted Jobsapplied to Impacted Jobs

Supervisors take actions Supervisors take actions to resolve exceptionsto resolve exceptions

Exceptions Management Rapidly Review and Resolve Issues







Enables you to…


…Without re-implementing or customizing

Parameter-Driven ConfigurationSet Up Quickly, Replicate Easily

Reconfigure… Define Controls… Use Parameters…

…By site, role, organization, department

…For controlling UI layout, application behavior, security,

content

• Offers high degrees of configurability and flexibility• Workstation can be configured at several levels • 27 parameters can be set at multiple levels


Direct Integration to Shop Floor EquipmentEnable Automatic Data Acquisition

MESMES

ERPERP

Corp &Mfg Mgmt



Shop Floor Control

MOC* or 3rd PartyData Integration

*Manufacturing Operations Center

• Standards-based integration with system automation & control devices

• Acquire information in real-time, without batch-synchronization delays

Eliminate transcription errors

Maintain only one source of truth

Eliminate ad-hoc device integration costs


Seamless Integration with Enterprise AppsReduce Integration and Maintenance Burdens


Shop Floor Control

MESMES


CustomerRelationship Mgmt

Supply ChainManagement

BusinessIntelligence

EnterpriseResource Planning

Reduce implementation costs

Reduce training costs

Reduce maintenance and support costs

• Fewer integration components to certify

• Fewer integration points to manage

• Fewer vendors to manage

• Improved reliability and security


Multi-Plant CapabilitiesReduce Unnecessary Expansion Costs

Only One System to Maintain• Common information platform• Common MES application• Common user experience

Decrease incremental costs incurred in supporting business expansionssuch as addition of a new plant to enterprise, acquisitions, etc.


• Set up quickly, replicate easily• Acquire equipment data automatically• Enable seamless enterprise information flow

Execute and Manage Shop Floor Functions Efficiently

Reduce SystemComplexity andIntegration Cost

Reduce SystemComplexity andIntegration Cost

Oracle Manufacturing Execution System

Improve Shop Floor Operator Productivity

and Efficiency

Improve Shop Floor Operator Productivity

and Efficiency

• Execute with timely, sequence-based information• Capture activity details quickly and accurately• Report exceptions for timely supervision

Increase Shop Floor Visibility and Reduce

Compliance Risks

Increase Shop Floor Visibility and Reduce

Compliance Risks

• Gain instant visibility of shop-floor conditions• Manage with top-floor insight into mfg conditions• Always know the source and placement of parts

Achieve Real-Time Responsiveness for

Greater Agility

Achieve Real-Time Responsiveness for

Greater Agility

• Minimize system response time• Execute against demand and capacity signals• Rapidly review and resolve exceptions




Improve Operator Productivity and Efficiency



Oracle Manufacturing Operations Center

The Foundation for Continuous Improvement in Manufacturing

Operations

Automation& Process

ControlSystems

ERPSystems

Users

PLC CNCMachines

DCS SCADASystems

AdvancedProcessControl

HumanMachineInterface

- MES- Quality- Cost Mgmt…

ManufacturingOperationsData Model

ManufacturingOperationsData Model

Role-BasedDashboards

Contextual-izationEngine

Corporate BI

Cross-PlantKPIs

HistoricalTrends

Plant-SpecificKPIs

Real-TimeUpdates

Device-Generated Data

Production ActualsSchedules

Item Master Data

ProductionManager

Plant Mgr /VP of Mfg

MES Shop Floor Communication Drivers


Appendix:

Manufacturing OperationsCenter Screenshots


Plant Manager Dashboard


OEE and Quality Trend – Month to Date


Current Shift Production By Equipment


OEE by Production Line


Click to view Click to view alert detailsalert details

Production Manager DashboardLine-Level Status


Equipment Equipment down signaldown signal

EquipmentEquipmentavailabilityavailabilitydistributiondistribution

Production Manager DashboardEquipment-Level View of Critical Process Parameters

EquipmentEquipmentoperatingoperating

parametersparameters

next generation manufacturing application - oracle · next generation manufacturing application ......

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