ngmes_frs

7/29/2019 NGMES_FRS

1/51

7/29/2019 NGMES_FRS

2/51

NG-MES- BI Reporting Functional Requirement Document

Cummins Inc

Business Intelligence Reporting

Version: 1.2

December 2006

7/29/2019 NGMES_FRS

3/51


Cummins Inc

Business Intelligence Reporting

Version: 1.2

December 2006

Confidentiality Statement

Recipients of this document will not directly or indirectly disclose the same to others or use

any such Data for itself or on behalf of others without the prior written approval of Cummins.

Any writing, drawing, diagram, electronic or other medium embodying the Data will be

returned to Cummins either upon completion of the services or delivery of the goods

Contractor has been retained to provide, termination of the agreement between Contractor

and Cummins under which such services are being provided or goods are being delivered, or

at Cummins request, and all copies will be destroyed.

7/29/2019 NGMES_FRS

4/51


Document Release Notice

Project Name : Business Intelligence ReportingDocument Detail :

Name Version Number Description

Functional

Requirement

Specification

1.2 Document Created

Document Control

This document and any revised pages are subject to document control. Please keep

them up-to-date using release notice from the distributor of the document.

Authored By: Date:

Approved By: Date:

Authorized By: Date:

Cummins Inc. Confidential Page 1

7/29/2019 NGMES_FRS

5/51


Abbreviations

Term Name Abbreviations

Assembly Management System AMS

Bill Of Material BOM

Business Intelligence BI

Before In Service BIS

Cummins Operating System COS

Central Data Warehouse CDW

Data Warehouse DW

Darlington Engine Plant DEP

Engine Serial Number ESNEarly Life Failure ELF

Entry Task Validation Exit ETVX

Functional Requirement Specifications FRS

Key Performance Indicators KPI

Next Generation Manufacturing Execution System NG-MES

Persistent Operational Data Store PODS

Parts Per Million PPM

Part Serial Number PSN

Rolled Throughput Yield RTYRadio Frequency Identification Device RFID

Structured Bill of Material SBM

Tata Consultancy Services TCS

Transient Operational Data Store TODS

Work In Process WIP


7/29/2019 NGMES_FRS

6/51

7/29/2019 NGMES_FRS

7/51

7/29/2019 NGMES_FRS

8/51


The analysis of this data would be based on standard industry wide used metrics and

Cummins COS metrics which would help define standards at the corporate level for

benchmarking plants against each other.

The requirements gathering and analysis phase would comprise of:

Understanding NG-MES footprint and the business processes and functionalities

that are covered

Defining the operational metrics and how they need to be derived and

delivered.

Defining the data needs for analysis, typical analysis trail, reporting

requirements from each NG-MES process/module

Functional and technical design of the mechanism to extract data, retain data

and deliver the data for analysis, metrics and reports Mapping the BI requirements (data/ analysis trail mechanism / reporting) back

to the NG-MES Apriso data model

Understanding the data transformations required

Understanding information needs and sources of data other than that existing

in NG-MES and analyzing how to satisfy those needs

Documenting BI requirements in a requirements specifications document and

presenting it to the data owners for approval

1.3 Deliverables

Functional solution design document incorporating the following:

o Definition of all metrics that need to be delivered through this solution

o Data requirements to deliver the metrics as well as the data sources and

transformation requirements

o Definition of Non-metric data requirements that needs to be extracted

and retained for analysis to manage MES process

o MES reporting requirements

The requirements document will provide mapping at data level between thesource and target systems.

1.4 Scope

The scope of this document is limited to the following:

Definition of Operational, Plant and Consolidated metrics for each process area


7/29/2019 NGMES_FRS

9/51


Only the process areas in manufacturing have been covered

Mapping of all the metrics to NG-MES

Gap Analysis

1.5 Assumptions

All functional areas within the affected entity are supportive of the project and

will be a part of the extended team during all phases of the project

The business intelligence project will be derived based on the NG-MES data and

hence any data changes will have to be analyzed together for impact analysis

1.6 Glossary

Term Name Description Abbreviations

Assembly

Management

System

An existing assembly MES application running in

most of the Cummins Inc. plant. This application

transmits assembly data to, and collects

assembly data from the shop floor, and provides

interfaces for scheduling, materials handling,

station configuration, assembly, and production

reporting activities.

AMS

Bill Of Material An ordered list of parts, subassemblies,

assemblies, that defines the product.

BOM

Block-set First operation of the engine assembly where

the block is kept on the carrier or pallet.

Completed Engine Engine that is manufactured and tested (no

longer in WIP) but not yet shipped to the

customer.

Cycle Time Time duration between an engines arrival at

the work-station and its departure from thework-station

Data-plate / Data-

tag

Engine information or Identification, which

contains details specific to an individual engine

such as Engine Serial Number, Customer name,

and Emission norms.


7/29/2019 NGMES_FRS

10/51



Dock Hold The process used to prevent engines from

shipping to the customer

Downtime The time during which an assembly station,section, or team is down (stops production)

during a scheduled production period

ECM Electronic Control Module

Engine Sequence The order in which engines appear in the line-

set schedule file.

Engine Serial

Number

Unique number that identifies an individual

engine.

ESN

Engine Status The status of an engine in WIP (Work In

Process). The defined states are Scheduled, In-

Production, Completed, Shipped, Stop Build,

Hold, Reject, In Repair, and Scrapped.

Failsafing Automated verification or feedback regarding a

required assembly operation of the components

or tools.

HOLD Engine Engine production is kept on hold, awaiting

some decision

IMS Information Management System The IBM

database used for the legacy applications

running on the Cummins Inc. mainframe.

IMS

In Production

Engine

The engine has been set into production (i.e.,

the block has been set)

In Repair Engine An engine routed to the repair area for a quality

defect

Kitting The process of making a kit. A kit is a

combination of loose or unassembled engine

components.

Line-set Scheduled work order or ESN which is sequenced

and ready for production

Line-set Schedule A schedule of sequenced work orders that

indicate which work order is to be built on a

given date in a specific sequence.


7/29/2019 NGMES_FRS

11/51

7/29/2019 NGMES_FRS

12/51



Scheduled Engine An engine that appears in the line-set schedule

but has yet to be firmed or line-set.

Scrapped Engine An engine, which cannot be repaired or a

completed engine without a valid work order.

Shipped Engine The engine that is shipped to the customer (no

longer in the plant)

Shop Order Unique Configuration of the engine against

which the customer places the order

Short Block An engine without the head(s). Includes the

crankshaft, camshaft, and pistons.

Stop Build Engine Engine build is stopped due to some reason

Structured Bill of

Material

Structured listing of BOM which is a parent and

child relationship

SBM

Throughput A measure of the number of engines that pass

through a given area of the assembly line during

a given time interval.

Torque The reading obtained from a torque wrench of

the force applied to tighten a bolt.

Upfit Parts, which are added after the paint process is

completed. For example, air compressor.

Work in Process A product which is in process of completion WIP

Work Order An order to manufacturing a product to be made

Work-station

A physical location where the work is

accomplished


7/29/2019 NGMES_FRS

13/51

7/29/2019 NGMES_FRS

14/51


Exit Criteria :

Exit Criteria define the basis on which a phase can be considered complete.

Usually, Exit Criteria of one phase form the entry criteria for the subsequent

phase of a project.

This assignment consists of the following phases:

1. Initiation

2. Requirement Analysis

3. Assessment

4. Define


7/29/2019 NGMES_FRS

15/51


Following table list the activities associated with each phase as per the ETVX model:

Phase Entry Tasks Validate Exit

Envision Project award

Milestones

expected

CUMMINSstandards for

documentation

CUMMINS brief on

the project

Identify Project Manager (TCS)

Formation of core team TCS as well as

CUMMINS

Kick off meeting Role definitions

Project plan discussion with activity

scope definitions

Discussion on deliverables

Understanding CUMMINS documentation

standards

Project plan

sign-off

Master Pro

Plan

Requirement

Analysis

Current KPI Lists

Apriso Reports

and formats

NG MES FRS

document

Others

Organize workshops for requirement

gathering

Identification of Information Needs

Review of existing systems with the

interface and data flow methodology in

place Identification of functionalities / KPIs /

Operational metrics required

Verification

and Validation

of the

Information

needs / KPIs

Informatio

needs / K

Template

Defined)

Assess KPI Template /

List

Identification of data flow for each KPI

Gap Analysis

Understanding the Data transformation

requirements

Validation of

Data flow

identified for

each KPI

Data Flow

table


7/29/2019 NGMES_FRS

16/51


Phase Entry Tasks Validate Exit

Define Information

needs / KPI

Template (User

Defined)

Data Flow table

Define / Design MES BI Logical Data

Model

Define Reporting Requirements

Validation of

Design

document

Sign-off o

Design

document


7/29/2019 NGMES_FRS

17/51

7/29/2019 NGMES_FRS

18/51


3.1 Operational Requirements:

Operational requirements consist of reporting needs of the plant assembly team for

successful assembly of the engine.

These are the operational reporting needs of the plant / assembly people for their day

to day operations.

All the operational reporting will happen from the Transient Operational Data Store

(TODS).

Examples of the type of business questions driving these operational reporting are:

1. What parts I need for pending assembly operations for the engines on-line?2. Is any station having continuous over-cycle time?

3. Am I having any missed cycles on any stations?

4. Am I having any parts shortages for engine assembly on the line?

5. Am I building any engines as short ships?

6. Did I have any failsafe overrides and who authorized it?

Based on these business questions the operational metric are derived. Below sections

detail the operational metrics per manufacturing area:


7/29/2019 NGMES_FRS

19/51


3.1.1Process and Assembly

Sr.No. Measures Units Definitions Reporting Dimensions Meeting Remarks

Time Based ResourceBased

Specifics

1 Number of gaps # Number of missed/starved cycles Per Station

Definition Will BeDefined. Need ToCapture In DW

2 Over cycle time per NounName

Min. Per Station

Per ESN

3 Failsafe parts exceptions #

Total number of Failsafe partsexceptions occurrences duringengine assembly

Per Station,Per Operator Per ESN

4 Failsafe station overrides #

Total number of Failsafe stationover ride exceptions occurrencesduring engine assembly

Per Station,Per Operator Per ESN

In addition to the metric listed above there is a need for operational reporting for successful completion of the assembly

operations. These reports have to be preconfigured in the application or the reporting server and should be available to the

assembly team when needed. Below is a sample list of these reports:

1. Kitting Sheet: Appendix 7.5

2. Build Sequence: Appendix 7.6

3. Bulk Picking List: Appendix 7.7


7/29/2019 NGMES_FRS

20/51


3.1.2Quality

3.1.3Material Requirement

Sr.No. Measures Units Definitions Reporting Dimensions

TimeBased

ResourceBased

Specifics

1

Production line breakdowndue to part unavailability

# Number of line stoppages due tounavailability of parts for assembly

Per AssemblyLine

Per ShopOrder, PerItem / Part

2

Short Ship # Number of Engines short shipped dueto unavailability of parts

Per ESN, PerShop Order


7/29/2019 NGMES_FRS

21/51


3.2 Plant Specific Reporting

These are the Plant specific reporting needs of the plant management for their

operations management.

All the plant specific reporting will happen from the Persistent Operational Data Store

(PODS).

Examples of the type of business questions driving this plant specific reporting are:

1. Whats my % of order completion?

2. Am I meeting delivery schedules?

3. How many engines did I scrap?

4. Whats my capacity utilization?5. Whats my total downtime?

6. Whats my current output performance or throughput?

7. Whats the status of repair?

8. How much time is being taken to build one engine?

9. Whats the % of defects?

10. How many engines were built right the first time?

Based on these business questions the plant specific metric are derived. Below

sections detail the plant specific metrics per manufacturing area. The hierarchy in

which some of these metrics are related is explained in Appendix 7.8.


7/29/2019 NGMES_FRS

22/51

7/29/2019 NGMES_FRS

23/51


9 Starved Time Hours Per definition of NG-MESStation Cycle Time StoryBoard

Per Shift,Per Day,Per Month

Per Station

10 Blocked Time Hours Per definition of NG-MES

Station Cycle Time StoryBoard


Per Station

11 Actual Working Time Hours AWT=Actual Available

Working Time - StarvedTime - Blocked Time


Per Station

Calculation To Be Done In DW

12 Utilization Factor % UF = Actual WorkingTime / Net AvailableWorking Time


Per Station

13 Performance Factor % PF = (Standard Cycle

Time)/(Actual CycleTime)


Per Station

14 OEE %

Not To Be Done In Warehouseas the formula for calculationis still not clear.

15 Equivalent 8-hour shifts # Available Clock Time / 8(-hrs)


Per Station

Calculations.

16 Highest average Noun Nameper 8-hrs shift

# The highest number ofNoun Name produced inan 8-hr shift as a monthlyaverage.


PerAssemblyLine

17 Demonstrated average dailyoutput (over the last 20 days)

# (Total output of goodNoun Name over the last20 days)/20


PerAssemblyLine

18 Highest demonstrated output # PerAssemblyLine

19 Current output performance # Per Shift,Per Day,Per Month

PerAssemblyLine

On A Daily, Shift, Day BasisTo Be Picked Up From NG-MES

20 Current vs. best performance % Current outputperformance / Highest

Per Shift,Per Day,

PerAssembly

Calculation


7/29/2019 NGMES_FRS

24/51


demonstrated output Per Month Line

21 Noun Names Shipped toOriginal Promise

% Noun Name shipped ontime to original promisedate.


PerAssemblyLine

Per ShopOrder

22 Noun Names Shipped toOriginal Customer RequestDate

% Noun Name shipped ontime to original requestdate.


PerAssemblyLine

Per ShopOrder

23 Number of Noun Names builtwithout requiring repair # Number of Noun Namesin the normal (designed)process flow.


PerAssemblyLine

Per ShopOrder

24 Number of Noun NamesCOMPLETED A STATUS, PASSEDA LOCATION, IN A CERTAINTIME FRAME

# Total number of NounNames built in a certaintime frame and at agiven location. This willincluding / cover thenumbers in the followingstatus:

Per Hour, Per End Of Shift,Calculated On TheProduction Start Date

Number of quality Noun Namebuilt

# Per Shift,Per Day,Per Month

PerAssemblyLine

Number of repaired NounName built

# Per Shift,Per Day,Per Month

PerAssemblyLine

Number of Noun Name

scrapped

# Per Shift,

Per Day,Per Month

Per

AssemblyLineNumber of Noun Name sent to

test# Number of Noun Name

shipped to testcomplete.


PerAssemblyLine

Number of audited NounName

# Number of Noun Nameaudited


PerAssemblyLine

Number of Noun Name taggedto ship

# Number of Noun Nameshipped to customers.


PerAssemblyLine


7/29/2019 NGMES_FRS

25/51


Number of Noun Namerepaired

# Number of Noun Namerepaired and ready forshipping.


PerAssemblyLine

Number of Noun Name, out ofprocess

# Number of Noun Namethat fall out of thenormal process flow. Atwhat locations. FromOverall OperatingPerformance (OPP)sheet. Used to calculateRTY.


PerAssemblyLine

Only Noun Name Which HaveGone Out Of Process

Number of Noun Namestandby for repair

# Number of Noun Namewaiting in line for repair.

Per Hour PerAssemblyLine

To Capture All Noun Name AtRepair Location, At LineRepair Spurs At A Given PointOf Time

Number of Quality Noun Namein storage

Number of quality NounName built but notshipped yet.


PerAssemblyLine

Per ShopOrder

Number of Quality NounNames per Hour

# (Number of quality NounName built) / (Totaloperating hours)

Per Hour PerAssemblyLine

Number of Quality NounNames RIGHT FIRST TIME per

operator

# (Number of quality NounName built) / (Totalnumbers of the operatorson shifts)


PerAssemblyLine

Capture Only Number OfOperators At Start Of Shift

25 Time building one qualityNoun Name

Hours (Total operating hours) /(Number of quality NounName built)


PerAssemblyLine

26 Rolled throughput yield (RTY) % 6 Sigma Rolledthroughput yield, RTY =(yield of process 1) (yieldof process 2) (yield oflast process).ThroughputYield of aProcess=(Number of NounName Built Correctly by


PerAssemblyLine

No To Be In DW


7/29/2019 NGMES_FRS

26/51

7/29/2019 NGMES_FRS

27/51


6 Number of Defects # Total numbers of defects observed in Noun Name Per Month Per AssemblyLine

Per ESN

3.2.3Material Requirement

Sr.No. Measures Units Definitions Reporting Dimensions

Time Based ResourceBased

Specifics

1 BOM Variations List Variations between EngineeringBOM, Shop Order and Actual BOM.This needs to be reported at item/ part level variations.

Per Month Per AssemblyLine

Per ShopOrder

2 Production linebreakdown due topart unavailability

# Number of line stoppages due tounavailability of parts forassembly


Per ShopOrder, PerItem / Part

3 Short Ship # Number of Engines short shippeddue to unavailability of parts


Per ShopOrder

4 Parts consumption

variation

# Variation in parts consumption in

real time (BOM variations) asagainst planned partsconsumption as per BOM

Per Month Per Assembly

Line

Per Shop

Order


7/29/2019 NGMES_FRS

28/51


3.3 Aggregate Reporting

These are the aggregate reporting needs of the management for their business

management.

All the aggregate reporting will happen from the Central Data Ware-house (CDW).

Examples of the type of business questions driving these aggregate reporting are:

1. How does Plant 1 compare to Plant 2 for:

a. Delivery performance

b. Quality performance

c. Capacity utilization

d. People/Engine/Day2. Whats my total production in a given period of time?

3. Whats the overall delivery performance?

4. What is the FG stock quantity and value?

5. What is the ELF PPM?

Based on these business questions the aggregate metric are derived. Below sections

detail the aggregate metrics per manufacturing area:


7/29/2019 NGMES_FRS

29/51


3.3.1Process and Assembly

Measures Units Definitions Reporting Dimensions Time Based Resource

BasedSpecifics

1 Total Noun Names Completed # Number of Noun Namescompleted all operations,

tests etc

Per Month, PerQuarter, Per Year

Per Plant

2 Utilization Factor % UF = Actual Working Time /Actual Available Working Time


Per Plant

3 Performance Factor % PF = (Standard Cycle Time)/(Actual Cycle Time)


Per Plant

4 Demonstrated average dailyoutput (over the last 20 days)

# (Total output of good NounName over the last 20days)/20

Per Month Per Plant

5 Highest demonstrated output # Per Quarter, Per Year Per Plant

6 Current output performance # Per Month Per Plant

7 Current vs best performance % Current output performance /Highest demonstrated output

Per Month Per Plant

8 Noun Names Shipped to OriginalPromise

% Noun Name shipped on time tooriginal promise date.


Per Plant

9 Noun Names Shipped to OriginalCustomer Request Date % Noun Name shipped on time tooriginal request date. Per Month, PerQuarter, Per Year Per Plant

10 Number of Noun Names builtwithout requiring repair

# Number of Noun Names in thenormal (designed) processflow.


Per Plant

11 Number of Noun Names

COMPLETED A STATUS, PASSED ALOCATION, IN A CERTAIN TIMEFRAME

# Total number of Noun Namesbuilt in a certain time frameand at a given location. Thiswill including / cover thenumbers in the followingstatus:


7/29/2019 NGMES_FRS

30/51

7/29/2019 NGMES_FRS

31/51

7/29/2019 NGMES_FRS

32/51


3.4 Reference Values

The reference values are those which remain constant over a fair duration of time. These values are used in calculating the

performance metric and derived based on engineering principles or business rules. These values are either stored in reference

systems or present in NG-MES. These values may require only a daily update and need not be updated on an hourly basis. The

mapping for them is shown in section 4.

Measures Units Definitions Meeting Remarks1 Available Clock Time Hours Calendar time subtracted by weekends, holidays, no-

shift time, breaks, lunch times, etc.Available Clock Time = Total OperatingTime. Will be available from NG-MESshift scheduler.

2 Scheduled Down Time Hours Hours for scheduled maintenance and scheduled toolchanging, etc.

May be available from NG-MES shiftscheduler as No schedule

3 Expected UnscheduledDown Time

Hours Time for unscheduled tool changing, periodic gauging,etc.

May be available from NG-MES ifconfigured by the plant.

4 Takt Time Min. Customer demand cycle time (Noun Name Orders /Working Hours).

Entered by plant as design constants.

5 Planned Efficiency % Expected efficiency after all losses, used to determinedesigned cycle time.

Entered by plant as design constants.

6 Planned Cycle Time Min. Designed line index time (calculated), used to

determine station loading and index time ofautomation.

Configurable by station in NG-MES. Will

be done by the plant.

7 Available time per shift Min. Total available time - planned breaks Will be available from NG-MES shiftscheduler.

8 Engineered Capacityper shift

# Available time per shift / Takt Time Calculation


7/29/2019 NGMES_FRS

33/51


3.5 Additional Metrics

These are the metric for which required data may not be fully available from NG-MES. To get the values / reporting for these

metric we need to fetch required data from other systems in Cummins environment.

Measures Units Definitions Remarks Reporting Dimensions Time Based Resource

Based

Specifics

CapacityUtilization

% Measure of theoretical capacityutilization. Number of good partsproduced / number of good partspossible at the standard machinecycle time at the bottleneckoperation for the type of parts run,assuming a 24 hours per day, 365days per year production

Theoretical capacity willhave to be calculated basedon inputs from othersystems. NG-MES will givethe number of good partsproduced.

Per Month,Per Quarter,Per Year

Per Plant

MachineUtilization

% Measurement of machine uptime atcritical process steps which tend tobe capital intensive and thereforeimpact overall throughput &efficiency of a plant. Number ofgood parts produced / number ofgood parts possible at the standardmachine cycle time for the type ofparts run, assuming a 24 hours perday, 365 days per year production

Number of good partspossible will have to becalculated based on inputsfrom other systems. NG-MESwill give the number of goodparts produced.


Per Plant

People/NounName/day

# Calculated number = (exempt +operations + support) / (total NounName shipped) / (equivalent 8-hrshifts worked)

NG-MES will provide thenumber of operators presenton assembly line. The figurefor other persons involvedwill need to be fetched fromAttendance system.


Per Plant


7/29/2019 NGMES_FRS

34/51

7/29/2019 NGMES_FRS

35/51

7/29/2019 NGMES_FRS

36/51

7/29/2019 NGMES_FRS

37/51


Current outputperformance

Rolled throughput yield (RTY)

Current vs. bestperformance

Production Efficiency

Noun Names Shippedto Original Promise

Right first time out of everyquality gateTorque to TurnPiston ProtrusionIPVTests

Noun Names Shippedto Original CustomerRequest Date

Number of Noun Name withrepeated repairs

Number of NounNames built withoutrequiring repair

Defects per Million

Number of NounNames COMPLETEDA STATUS, PASSEDA LOCATION, IN ACERTAIN TIMEFRAME

Production line breakdowndue to part unavailability

Number of qualityNoun Name built

Short Ship

Number of repairedNoun Name built

Number of NounName scrapped

Noun Name sent to

test

Number of auditedNoun Name

Noun Name tagged toship

Noun Name repaired

Number of NounName, out of process

Noun Name standbyfor repair

Quality Noun Name instorage

Quality Noun Namesper Hour

Quality Noun NamesRIGHT FIRST TIME

per operator

Time building onequality Noun Name


7/29/2019 NGMES_FRS

38/51


Rolled throughputyield (RTY)

Current throughputtime per Noun Name

Production Efficiency

Right first time out ofevery quality gateTorque to TurnPiston ProtrusionIPVTests

Number of NounName with repeatedrepairs

Defects per Million

Repairs per NounName Type

Shift wise RejectionRate

Number of Defects

BOM Variations

Production linebreakdown due to partunavailability

Short Ship

Parts consumptionvariation

M

ES+OtherSystems

Available Clock Time Capacity UtilizationScheduled Down Time Machine Utilization

Capacity Utilization People/Noun Name/day

Machine Utilization

People/NounName/day

Material cost per NounName

ExpectedUnscheduled DownTime

Takt Time

Planned EfficiencyPlanned Cycle Time

Available time per shift

Engineered Capacityper shift

Other

Inventory Reserved BIS/OEM Defects

Inventory ELF Defects


7/29/2019 NGMES_FRS

39/51


Systems

BIS/OEM Defects

ELF Defects


7/29/2019 NGMES_FRS

40/51


5 DEP IMPLEMENTATION PRIORITIES

The first implementation of NG-MES is planned at DEP. Hence all the performance

metrics were reviewed by DEP team and priorities were set for each of the metrics.These priorities were further reviewed by Bob Borchelt and additional priorities were

identified.

Based on the priorities set by Bob and DEP and complexity of each metric a Metric

Priority Score was calculated. Higher the score higher was the priority for the metric.

The scoring technique adopted was:

Data: Present within MES = 9 and Outside MES = 1, Weight age = 6

Metric computing complexity: Low = 9, High = 1, Weight age = 3

Number of Required Dimensions: Less than or equal to 2 = 9, More than 2 = 1,

Weight age = 3

Report: Out of PODS = 9, Out of Star Schema = 1, Weight age = 3

Bob Borchelt Priority: High = 9, Medium = 3, Low = 1, Weight age =

DEP Priority: High = 9, Medium = 3, Low = 1, Weight age = 9

Based on the final scores the priorities were set:

Score greater than 175 = High Score between 126 to 175 = Medium

Score less than 126 = Low

Those marked High would ideally be available in the first release when DEP goes live

in August, Medium would be beneficial to DEP but the plant could wait for a later

release if the development teams are time constrained in development. Those marked

Low are unlikely to be utilized at DEP in the near future.

The following tables highlight the priorities set by the DEP team along with their

comments:

The notions used to depict the priority are:

H = Essential at launch, a High Priority

M = Useful after launch, a Medium Priority

L= Not required / Low Priority


7/29/2019 NGMES_FRS

41/51

7/29/2019 NGMES_FRS

42/51


6 ENGINE GENEALOGY

The Engine History Database (EHD) is a highly integrated system that processes and

stores detailed information on engines produced by Cummins Engines Inc as well as bythe Joint Venture plants.

The information is accessed by many part of the organization like:

1. Engine Plants

2. Product Performance

3. Accounting

4. Claims Administration

5. Marketing

Objectives of EHDB

Collect and store engine information on a worldwide basis

Consolidate engine information into a central file

Support interfacing business processes

Provide more timely access to engine information

Provide capability to perform analysis on data

Figure 3: Engine History Database Structure


Engine History

ESN

Plant

Info

Misc.

PaymentMCS Engine

Invoice

Sales Bonus/

Service Comm

Accruals

Payment Notes

Component

Serial

Number

Customer

InfoCustom

Registry

Build Date

Ship Date

SON

Config. Number

Date in Service

Equipment Model

Engine History

ESN

Plant

Info

Misc.

PaymentMCS Engine

Invoice

Sales Bonus/

Service Comm

Accruals

Payment Notes

Component

Serial

Number

Customer

InfoCustom

Registry

Build Date

Ship Date

SON

Config. Number

Date in Service

Equipment Model

7/29/2019 NGMES_FRS

43/51


Figure 4: Information Flow into EHDB

The As Build Data mentioned in the figure 4 is the As Built Manufacturing

Genealogy of the engine. It includes summarizing and reporting information about

material or components, personnel and equipment actually used to produce product as

well as other relevant genealogy data like production or process data and test results.

The NG-MES will collect and store the as-built information associated with each ESN.

The information collected can be made up of the following items:

1. Serialized Component Part Numbers

2. Serialized Component Lots Numbers

3. IPV test values

4. Operators that assembled

5. Defects recorded \ Repairs

6. Shop Order information

7. Ship information

8. Equipment identification and other details that need to be captured during

engine manufacturing (for selective equipment)

9. Process data required against engine history (for selective operations)


Engine History

Database

Engine Order

Management

Product Performance

System

Managerial

Accounting

Component

Serial Number

World Wide Claim

Process

Engine Billing

System

Claims Admin.

System

New Engine

Inspection System

Customer Info, In-service InfoBuild Data, Ship Data Invoice Cost Accruals

Service Information Major Components Info.

Build Data, Ship Data

Major Component Info

Service information

Invoice, Cost

SB/SC Accruals

Engine History

Database

Engine Order

Management

Product Performance

System

Managerial

Accounting

Component

Serial Number

World Wide Claim

Process

Engine Billing

System

Claims Admin.

System

New Engine

Inspection System

Customer Info, In-service InfoBuild Data, Ship Data Invoice Cost Accruals

Service Information Major Components Info.

Build Data, Ship Data

Major Component Info

Service information

Invoice, Cost

SB/SC Accruals

7/29/2019 NGMES_FRS

44/51


NG-MES Tracking and genealogy module will maintain the Work in Progress (WIP)

location / status of the engine (Tracking) and capture and maintain the information of

the assembly activities for Parts, Sub Assemblies, personnel, equipments and process

data (Genealogy) of the engine.

Figure: Engine Tracking and Genealogy Data Flow

Different scenarios where engine would be tracked are descried as below

# Area Description

1 Production Line

- On a CarrierEngine

NG-MES would generate a serial number / or the Engine Serial

Number (ESN) for every block set engine. NG-MES wouldattach a Work Order Nun. / ESN to the unique ID of the

carrier / pallet / engine RFID / Bar Code carrying the engine

block. Reading the Carrier / Pallet / Engine ID through RFID

reader / Barcode Reader in a specific area would determine

the engine location and system would update the WIP status

in IMS / ERP System depending on the plants process model


EQUIPMENT

7/29/2019 NGMES_FRS

45/51


2 Production Line

- Offline Engine

Due to reason such as repair, if the engine is offline the

system would track the engine by manual entry of the

location code against that WON/ESN entered by the operator

before the engine is taken off the carrier. As the WIP Status

update is based on manual entry, system will show the last

manually entered value. Once the engine is back on the

carrier, normal tracking system is enabled

3 Finished Good

Engine

System would allow a location code, bin number or the skid

number to be entered against an engine in COMPLETED status.

Based on this manual entry, the system would track the

engine in FG Inventory. This would be an option the plants

could choose. The location, bin number and skid number

should be able to be changed as engines are moved around in

the Test and finished goods area.

Different genealogy components for engine history are described in table below

# Genealogy of Description

1 Component

Verification

NG-MES would prompt the operator for Part Number details

(Bar Code or Manual Entry) and validate the details with the

engine build database (SBM). In case of deviation, system will

prompt the operator to reconfirm, if there is still a deviation

the system will require an override to be selected and a pre-

configured reason code. The engine would then be marked

with a defect and require inspection prior to being

completed.

2 Serialized

Components

NG MES would prompt the operator for a parts Serial

Number, the serial number can be scanned or typed and will

be recorded with the ESN for genealogy.

3 Serialized Lots NG MES would record the lots serial number for each ESN that

is built in the station and requires the serialize lot part

number.4 Sub Assembly System would generate the Part Serial Number (PSN) for the

sub-assembly components and keep the log of the

subassembly components part details for Sub Assembly

genealogy and finally these details would be attached to the

Engine genealogy when the Serial Number of the component

was scanned.


7/29/2019 NGMES_FRS

46/51


5 Fail Safing

Parts

System will log the As-build parts pick details for engine

genealogy. The system will also record a defect or short build

for any failsafing override and which failsafe was over ridden.

6 Torque Data System would prompt the operator for the desired number of

torque counts for the Assembly Station for guidance and

validation purpose. System would log the actual torque

data(s) for Engine genealogy for that station if required by the

plant.

7 Testing /

Process Data

System would display the test result - PASS / FAIL information

based on the real time information from the test. The system

would record the test and its results along with any failure

code or comments for engine genealogy

8 Personnel System would log the operator details for the workstation.

Operator can be logged into only one station at a time.Supervisors can have multiple logins at the same time.

9 Equipment System would log the equipments details such as equipment

number, tool number, equipments operational parameters etc

for a workstation for engine genealogy


7/29/2019 NGMES_FRS

47/51


An example of engine genealogy report used today is given below:

Engine Serial Number: 46376156

Engine Header Information:Bill To Cust Nbr : 56330 Ship To Cust No : 56331

Ship To Cust Name : Configuration Nbr : D413038MM02Model Name : QSC8.3-490 HO Publication Flag :

Fuelpump Part Nbr : 4088866 Fuelpump Cal Code : GW59Cpl Nbr : CPL8017

Shop Order Information:SO

TypePlant Name SO Nbr Start Date Eng

Build/UpfitDt

Eng Ship Dt Opts/Parts

Upfit2 DISTRIBUTOR UPFIT ESN46376156 06-MAY-2004 06-MAY-2004 07-MAY-2004 Opts / PartsUpfit1 CHARLESTON SITE GROUP SO86209 05-APR-2004 23-APR-2004 23-APR-2004 Opts / PartsBuild CONSOLIDATED DIESEL CO. SO23358 27-FEB-2004 03-MAR-2004 18-MAR-2004 Opts / Parts

For samples of suggested engine genealogy reports please refer to Appendix 8.10

Please see Appendix 8.11 for Minutes of Meeting for Engine Genealogy Reports.


7/29/2019 NGMES_FRS

48/51

7/29/2019 NGMES_FRS

49/51



7/29/2019 NGMES_FRS

50/51


8 APPENDIX

8.1 Bill of Material Levels Document

8.2 COS Performance Metrics

8.3 FlexNet Standard Reports Document

8.4 FlexNet NG-MES Database Documentation

8.5 Kitting Report Sample

8.6 Build Sequence


Bill of materiallevels.doc

COS PerformanceMetrics.xls

FlexNet StandardReport.doc

FlexNet_NG-MES_DatabaseDocuments.do

KITTING.pdf

Build Sequence.pdf

7/29/2019 NGMES_FRS

51/51


8.7 Bulk Picking List

8.8 Metric Hierarchy

8.9 Machining Metric List

8.10 Engine Genealogy Report Suggested Samples

8.11 Engine Genealogy Reporting Requirements

Machining Metric

List.xls

Bulk Picking List.pdf

Metric Hierarchy.ppt

GenealogyReports.xls

Genealogy ReportingMeeting Minutes.doc