Request for Information

Manufacturing Execution System

RONAL AG

List of Content

Introduction .................................................................................................................................... 3 1.1 1.2 1.3 1.4 Company profile...................................................................................................................... 3 Locations ................................................................................................................................. 3 Standard process step ............................................................................................................. 4 Specials.................................................................................................................................. 10

Project information ....................................................................................................................... 11 2.1 2.2 2.3 2.4 Motivation............................................................................................................................. 11 Objectives.............................................................................................................................. 11 Project organization .............................................................................................................. 12 Project timing ........................................................................................................................ 12

Basic functionalities ...................................................................................................................... 14 3.1 3.2 3.3 3.4 3.5 3.6 APS module Requirements ................................................................................................... 15 Visualization and Monitoring ................................................................................................ 15 Report ................................................................................................................................... 16 Traceability-Requirements .................................................................................................... 17 Human Resource ................................................................................................................... 17 Energy Management ............................................................................................................. 17

System and Software Requirements............................................................................................. 18 4.1 4.2 4.3 4.4 4.5 4.6 4.7 General MES Requirements .................................................................................................. 18 Supported Systems and approved Standards ....................................................................... 20 Business continuity / Emergency requirements ................................................................... 21 Definition of required Interfaces .......................................................................................... 22 System Architecture .............................................................................................................. 24 User/Account Management and Permissions concept ........................................................ 24 Customizing/Personalization Capabilities ............................................................................. 25

Implementation Concept .............................................................................................................. 26

Introduction

This document describes the functional specification of Ronal as a request for information.

1.1

Company profile

RONAL is a leading manufacturer of light alloy wheels and shower enclosures. RONAL stands for cutting edge technology, creative design and uncompromising quality. Quality is RONALs philosophy. RONAL was founded in 1969 and soon became one of the pioneers in the global market for light alloy wheels. Besides its production of wheels, RONAL has been focused for the past 28 years on the production of shower enclosures as well. RONAL's philosophy is centered around three principles; customer focus, innovation and quality work. These principles are responsible for the continuous growth of the company.

1.2

Locations

Due to RONAL's international manufacturing network, it is able to work with competitive cost structures and it is able to serve its customers locally. RONAL supplies and takes care of its customers directly from Germany, Spain, Czech Republic, Poland, Italy, Mexico and the USA. In order to safeguard the highest quality, RONAL manufactures its own production tools. The production of the tools takes place in both Portugal - Cantanhede - and Switzerland - Hrkingen. Apart from the tooling department, Hrkingen also accommodates the Research & Development department and the headquarters of the group. This geographical and organizational structure secures short development times at the highest quality and know-how levels.

1.3

Standard process step

Process Melting Input Aluminum alloy AlSi7MG or AlSi11MG with about 600 900kg Aluminum chips from the production Scrap wheels Processing Pouring of the melt out of the oven to transportation ladle Preparation of melting cleaning with argon or forming gas impeller purging Manpower 12 operators / 4 shift model Process in numbers Process temperature about 750C 785C Energy demand about 110 1350 m3 gas/ton Output Aluminum melt of both alloys AlSi7MG or AlSi11MG

Process Casting Input Prepared melting AlSi7MG or AlSi11MG in the ladle with about 850 1500 kg Wheel data via conveyer to the next process Compressed air for feeding of the mold and cooling of the air (8-16 cooling cycles) Filter for the melting (oxide brake) Processing Visual quality control Eliminate the casting fin Mold temperature about 485C 560C Transportation via conveyer to the next production step Cycle times about 250 380 sec/wheel Raw cast weight about 9 35 kg Manpower about 5 operators per shift per 12 casting machines / 4 shift model Process in numbers Temperature of the melting in the casting machine about 680C 715C step Output Raw cast wheel AlSi7MG or AlSi11MG

Process X-Ray Input Raw cast from the conveyer Wheel data from the conveyer X-Ray programs Processing Transportation with conveyer to the next process step High dynamic radio scope up to 30 pics/sec Manpower about 4 operators / 4 shift model Output Raw cast wheels X-rayed i.o. wheels to next process step n.i.o. wheels to scrap

Process in numbers Cycle time about 40 sec/wheel

Process Degating Input X-rayed wheel i.O. Wheel data from the conveyer Allocated tool Processing Transportation with conveyer to the next process step Manpower about 4 operators per shift Process in numbers Cycle time about 30 sec/wheel Output Raw cast wheel degated

Process FlowForming (FF) Input X-rayed wheels i.O. degated FlowForm tools FlowForm programs Processing Transportation via palette/conveyer to the heat treatment Wheel temperature during the process about 340C Manpower 1 operator per shift Output Flow formed wheels i.o. wheels to next process step n.i.o. wheels to scrap

Process in numbers Cycle time about 60 sec/wheel

Process Heat treatment Input AlSi7MG wheels X-rayed i.o. degated FlowFormed i.o. Output Wheels heat treated Partly wheel data via barcode

Processing Transportation with conveyer/palette to machining

Process in numbers Cycle time solution heat treatment about 280 min with about 540C Quench hardening about 65C Cycle time artificial aging about 180 min with about 155C Manpower about 3 operators per shift

Process Machining Input Wheels AlSi7MG or AlSi11MG Heat treated and FF in AlSi7MG Wheels AlSi11MG x-rayed i.o. degated Wheel identification and machining programs Processing Transportation with conveyer/palette to washing and leak test Process in numbers lead time for the whole machining process steps about 6min//wheel Manpower 1 operators per shift per line n.i.o. wheels to scrap Output Machined wheels i.o. wheels (via drawing) (turned, drilled, balanced and pre-deburred)

Process Balancing Input Machined wheels after washing and leak test with helium Programs for the balancing n.i.o. wheels leak tested/balanced to scrap Processing Transportation with conveyer/palette to deburring Manpower 1 operators per shift per line Process in numbers Cycle time 30 sec/wheel i.o. wheels Output Machined wheels

Process Brushing / Deburring Input i.o. wheels washed, leak tested, balanced manpower Processing Transportation with palette to surface finishing Output i.o. wheels brushed and deburred n.i.o. wheels to scrap Process in numbers Cycle time manual deburring about 2-10 min/wheels (depends on design) Cycle time brushing about 1 min/wheel Manpower 1 operators per shift per work station

Process Painting Input i.o. wheels deburred Formulation for painting Paint systems Processing Wheels direct via roller belt to finished goods control Paint layer intensity with 3-layer-paint about to storage to next production step 150 180 my Manpower about 15 operators per shift Output Painted wheels i.o. wheels as customer specification n.i.o. for rework or stripping or scrap

Process in numbers Capacity about 500 wheels per hour

Process Storage/Shipping Input Wheels painted with quality control i.o. Labels Instruction for logistic Packaging material and loading equipment Processing Shipment to the customer Process in numbers Manpower about 8 operators per 4 shift Output i.o. wheels painted to customer specification packaged and prepared for shipping

1.4

Specials

Process Front Facing Input Wheels painted 2/3-layer-paint Front Facing-programs (turning programs) Mirror lathe Processing Transportation with palette to painting area for transparent finishing Process in numbers Manpower 1 operators per shift per machine Output Front Faced i.o. wheels with basis 2/3-layer paint

Process Multi Color Rim (MCR) Input Wheels painted 2-layer-base coat and contrast paint Front Facing-programs (turning programs) Mirror lathe Processing Transportation with palette to painting area for transparent finishing Process in numbers Manpower 1 operators per shift per machine Output Front Faced i.o. wheels with 2-layer-base coat and contrast paint Colored base coat appears at the Front Faced surface

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2 2.1

Project information Motivation

The motivation of the project is to have a standardized conception of functionalities to control the production with each steps included. Optimized planning and control of resources (machines, manpower) and processes o Visualization of production monitoring for control Traceability of a wheel (whole lifecycle from Aluminum purchase till shipping to customer) Optimized visualization of information (reporting) Control with production orders based on feedback of the production o Cycle times, lead times, scrap (on time during a production day) Planning of change overs during a production day Planning and documentation of manpower during a production day Visualization of the production (quantities) and process parameter o o o o Real time History Definition of borders tolerances Warning function (signal/information/) with overrun the borders

Monitoring of the production, the quality and the process parameter

Access control Reporting o o o o KPIs Reports for production (monthly, daily) Energy consumption (Co2-bilance) Maintenance

Documentation of down times, machines and tools

2.2

Objectives

The main goal is the increasing of the economics of scale with controlling the production based on measured values. Measured goals are defined: Traceability of the availability of machines Reducing of non-productive time o o o o o o Systematically change overs Increasing the OEE Productivity, Availability, Quality Management of production processes Accelerate of crucial production processes Harmonized manufacturing landscape Consolidation of applications

To achieve the goals we need to gather all production, process and quality related process parameter in ONE consistent data base to visualize, control and trace.

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2.3

Project organization

Orderer of the project is the Chief Officer Operation Thomas Trampenau. Project manager: Ulrike Buchholz (Operations)

Core Team consists of: Jacek Cyrwus (Plant manager) Holger Girmond (ERP - XPPS) Patrick Huber (IT Strategy) Rafal Karolewski (Support implementation in the 1 plant W06) Thomas May (Quality) Thomas Trampenau (COO) Manfred Wirth (Infrastructure)
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2.4 Project timing We defined different project phases with the timing for the first plant. In the following picture are shown the main steps including the time line.

The main steps are divided in sub steps Analyses and rough specification (phase 1) o o o o Definition of basic requests at MES Project draft --> request specification Long list based on rough specification Reducing long list with defined criteria to short list max. 3 supplier

Clarify request (phase 2) o o o o o Adjustment of requests with the system provider Consulting o provider based on conception and implementation Definition of necessary investments contract specification with implementation guide, costs, dates Choose of system provider

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Detailed conception (phase 3) o o o o o o o Evaluation of quotation and selection of supplier for phase 3 Definition of detailed integration in existing IT-systems for data transfer of master data Definition of necessary configurations in the system (user admin, rights,) Definition of surfaces and layouts, e.g. at gathering station Definition of basic conditions for corporate standards: standard inspection plans, standard attribute Definition of evaluation Decision of the right system provider

Developments of system supplier Test environment o Define test environment start and test in a small area

Realization of "pilot" (for each department) and training o o o o Training of defined staff Installation of hard- and software for "pilot" (reduced request) Integration master data Checkout of test environment (production environment) o o Automatically data collection Manually data collection

Adjustment and optimization of configuration, layouts, user surface, Preparation of standard reports and analysis

Implementation and active phase 1st plant o o o o o o Master data transfer Connection to existing systems for data collection Test planning Employee training Data collection Roll-out at plant

Business operation o o Regular business Maintenance and system maintenance

Review Roll-Out RONAL Group

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Basic functionalities

Different main functionalities are defined and combined to MES-modules. One of the main integrated documents describes in detail the expected functions in form of a checklist.

The Ronal MES is focused on the following main functionalities: APS Visualization and Monitoring o Includes also History, Escalation, Documentation

Reporting Traceability Human Resource Energy Management

The next chapters describe some of the functionalities in detail, the others are covered in the checklist.

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3.1 APS module Requirements Please note: The detailed requirements of the sub-functionalities can be found in the corresponding checklist. Ronal uses the ERP system Infor XPPS for the execution of all operational and economic aspects. This includes the following main modules and main processes (Not all modules and processes are used in its entirety and there are also differences in the use of these between the individual plants): EDI communication with customers and suppliers Order processing for OE and AM customers Warehouse and revolving inventory management Material and (capacity) planning (MRPII) Purchasing procurement Production planning Shop floor order handling Data collecting and data feedback from the shop floor

The APS module should be positioned as a detailed planning system for the shop floor, which is based on the higher level planning data (e.g. mid- and long term production plan) and on the shop floor orders from the ERP system. The main objective of the APS module should be the visualization of the ERP shop floor orders, the ability to schedule (within certain limits and boundary conditions) the shop floor orders in a more detailed matter, to visualize the production situation and to visualize the ongoing production results and show the impact of them to the shop floor orders and the production situation.

3.2 Visualization and Monitoring Please note: The detailed requirements of the sub-functionalities can be found in the corresponding checklist.

Visualization It is very important, that the system is flexible and able to modify. All interfaces should be possible to change manually. Also important is to have some library with basic animations, graphs, charts and so on. There should be the possibility to show information not only on computer screens also on dashboards, big screens located on production or even on tablets and Smartphones. The visualization should be possible real-time and history.

History There has to be the possibility to store/save historical data and have a constant access to them. Also the system back up should be continuous.

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Monitoring The system should be able to monitor process parameter of machine status and the production process, also of the product quality.

Escalation There should be the possibility to define warn limits and reactions for each warning ( sound signalization, sending reports or work orders to declared employees) and also the kinds of reactions. There should be the possibility to define the reaction of a warning e.g. stopping a machine or slowing down the process and so on.

Documentation This functionality should be able to administer programs, e.g. NC-programs.

3.3 Report The solution provides data pools or cubes which come in a standard database format (e.g. SQL) and can be analyzed. Reporting uses the existing Ronal tools (EIS / EIP from aruba informatik GmbH). To analyze it is very important to have statistic tools and history record. We need to be able to analyze data in Excel as well. One helpful tool could be value stream mapping. From the MES system we could get all the information we need to make a value stream map and generate it for each part There should be an easy way of generating and sending reports to different employees.

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3.4 Traceability-Requirements Please note: The detailed requirements of the sub-functionalities can be found in the corresponding checklist. Definition: capability to trace a product from its origin through processing, delivery and receipt, to its final location. The MES system module Traceability enables RONAL to trace wheels in both directions, back and forward, the minimum level of traceability is defined as lot traceability and where applicable on a piece level. A unique identifier (serial number) printed on the casted wheel will be used for identification and allocation of data to each product during production process. The traceability system will link the serial number to process and quality data including time stamp. After entering a unique serial number it is possible, to identify the relevant process and quality data of that product and by linked XPPS shipment information to identify which customer has been supplied with this product. It is possible to identify products by entering process or quality data or combinations of these (using Boolean expressions) and to receive all relevant wheels that have been produced during these conditions. As production results and quality information are gathered in local time zones, the traceability database needs to be using UTC time stamp.

3.5

Human Resource

Please note: The detailed requirements of the sub-functionalities can be found in the corresponding checklist. The system should support with the calculation of bonus for workers according quality and quantity. The system should make one base for working schedule and one for work orders. For the management it is also important to have all employees and their schedules in one data base. The system should be able to generate reports, considering parameters, groups and individual employees.

3.6 Energy Management Please note: The detailed requirements of the sub-functionalities can be found in the corresponding checklist. The main functions are covered in the Ronal Energy Management System EMS, but partly functions has to be covered be the MES.

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4 4.1

System and Software Requirements General MES Requirements

Please note: for almost all of the described requirements the following paragraphs there is a corresponding section in the detailed checklist that has to be completed as part of this RfI process.

IT Strategic Directions (Excerpt) IT as Business Enabler overcome the cost only notion push/emphasize the strategic value/benefits demonstrate and deliver on promises

Unify and Simplify Standardize and consolidate Reduce complexity

Optimization and Globalization Global first: whenever meaningful, global solutions and globalized systems will replace locally implemented solutions Shared services: instead of providing the same IT service multiple times per plant/country but in slightly different flavors, we will see more global IT services provided by one location for the whole group Globalize IT Team and processes (e.g. support based on ITIL)

System Maintainability Ronal aim at least effort maintainability. This means that the ongoing efforts to keep the system secure, stable, bug-free and current has to be minimal. In order to achieve this the maintenance process has to be highly automated, the software update cycle has to be structured and needs to follow a clearly defined schedule. System updates must not impact existing/already implemented configuration adaptations and customizations.

Maintenance & Support The support processes are clearly and transparently defined and aligned with Ronal company structure and needs. Different support scenarios and cases are clearly defined and have transparent SLAs.

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Volumes/Quantities for Server and Database Sizing Based on the process parameter documentation Ronal works with about 1023 process parameters in total. The breakdown of the total is as follows: Priority 1 (unimportant): 25 Priority 2 (important):114 Priority 3 (very important): 884

Taking prio2 and 3 together leads to rounded 1000 parameters multiplied by estimated 18 million produced wheels per year results in 18 billion records a year given that MES is in a fully deployed and productive status! Assuming one record is 10 kB (kilobyte) in size will give us an estimated yearly data volume of 180 TB (terabyte = 10
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Byte = 1.000.000.000.000 byte).

Integration into existing IT Landscape The solution has to integrate seamlessly into the existing IT landscape. The required integration is twofold: on one hand it is the office network with the superordinate ERP/PPS (primarily Infors XPPS) layer, on the other hand it is the production network with the subordinate machine and automation layer with its machine control (PLC). Technology-wise this translates into Wintel and IBM iSeries hardware on the ERP/PPS side and full variety of PLCs (Siemens, Fanuc, Danobat, Deawoo, Omron, Hitachi etc.) on the machine and automation side.

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4.2

Supported Systems and approved Standards

Databases and data formats

Due to data integrity reasons data records have to be stored in Unicode format. Supported database standards are: Priority 1: MS SQL (2008 and higher); optionally Oracle (10.x and higher) or DB2 on IBM/OS400. Distributed databases (e.g. master-slave concept) have to be available and supported.

Hardware/OS
Server: Priority 1: HP Intel with Windows Server 2008 R2; optionally IBM iSeries with OS/400. Client: Windows 7; required is an out-of-the-box integration with MS Office 2010 and Exchange 2010 (e.g. for notification service).

Network
LAN: All locations have Ethernet TCP/IP based LANs, using MS Active Directory as the central objects directory/repository. Some locations additionally have special purpose WLANs (e.g. providing Internet access for non-Ronal visitors or wireless access points in production facilities). Usually the office and production networks are physically and/or logically separated for example by means of VLANs. Historically there are still a few legacy protocols in use in some areas of some production networks. WAN: The Ronal locations are connected thru LAN-to-LAN VPN connections (over the Internet). Bandwidths vary from 2 Mbps up to 100 Mbps. Connection types involve xDSL, FC, Ethernet and MPLS. Most of the locations have a backup line in place however those capacities are minimal. All locations are shielded from the Internet by firewalls.

System Security Concept

The MES solution will be another system within the Ronal corporate network boundaries; as for all other already existing internal systems the same usual concepts, rules and policies will be applied. The various components which are part of this concept can be expected to be there and available. The only requirement - as far as the MES solution is concerned is that it doesnt interfere with the existing system security concept and its applications.

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Data Security Concept

Data security is critical for the MES solution and comprises basically protecting a database from destructive forces and the unwanted actions of unauthorized users. In addition to what one can expect in this context on the facilities, hardware, OS and database level as means of addressing the potential issues (such as encryption or strong user authentication) we expect additional application based approaches to protect the MES database from data security breaches. As an accompanying feature we expect a full audit trail which keep track of all actions and activities that involve any MES application and data object. With his all modifications can be traced back.

Backup/Restore Concept
The MES data will not be treated differently than any other business application data if it comes to backup/restore. What we expect here is that the MES solution a) does work with any professional Backup software and b) the MES solution adds features that optimize the backup and restore process, e.g. time-wise.

4.3

Business continuity / Emergency requirements

High availability
The solution is expected to support high availability solutions (application and database/ data storage layer).

Data history, archiving and reorganization

The solution has functionalities for archiving, data history creation and keeping as well as data reorganization. Archived data is separated from productive (live) data but still accessible by the so lution.

Centralized master data management

Master data records (e.g. for parts, suppliers, customers) are centrally manageable within a tenant as well as cross-tenant (across the group). Defined data ranges and/or data fields (within a data range) can be administered on a per plant basis.

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4.4

Definition of required Interfaces

Data interfaces
The solution comes with a variety of out-of-the-box interface options. XML, CSV, Text (ASCII), ODBC und LDAP have to be supported as a minimum. Data import and export have to happen in a manual and automatic way (batch and sequential recurring).

Data Entry Interfaces

The solution provides interfaces with which manual data feedback from various other systems (e.g. final goods inspection etc.) can be integrated into the MES or with which these systems can directly be connected to the appropriate MES functionality (e.g. final goods inspection: Touchscreens are directly linked to a MES module).

Office Integration The solution offers out of the box MS Office 2010 integration. This means for example MS Office 2010 applications can be directly launched from within the MES solution, MS Office 2010 file formats can be handled by the MES solution and data can be imported and exported from/to MS Office 2010 and the MES solution.

Interface to ERP
The solution can work with a bi-directional interface to the ERP system. The system can work with all parameters from the ERP system which are related to planning and scheduling of production orders, so that this data does not have to be captured into two systems. Data which is not provided by the ERP system can be maintained as master data in the system and has to be linked to the data from the ERP automatically. The interface from the ERP system (ERP to MES) should handle following data: Parts master Tooling and additional equipment master Machine and work center master Production orders header Work cycles Material information (BOM) Machines and work centers Tools and necessary equipment

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The interface to the ERP system (MES to ERP) should handle following data: - Actual production cycle times - Actual production rates (i.O. rates, rework rates, scrap rates) - Planning results (start date, end date, machines etc.)

Interface to Maintenance system

The solution provides an interface to Ronals maintenance system EAN. Information which is send to the maintenance system is for example (detailed data requirements have to be defined in a workshop phase): - Machine status (setup, production, inspection, maintenance) - Actual production numbers per machine, mold or any other tool

Interface to Energy Consumption

The solution provides an interface to Ronals Energy Consumption S ystem EMS.

Interface to Resource/Shift planning

The solution provides interfaces systems and is able to work with the shift model systems which are maintained in the HR-Systems and is able to work with the daily time attendance and absence records. Staff and shift master data should be used from the existing systems wherever the necessary data is maintained in these systems (HR and Time attendance systems).

CAQ/QA/QM Interfaces The CAQ interfaces are covered in the RFI of the CAQ-project.

Machine (Controls) Interfaces

The solution should be able to handle and work directly with data from machine controls, OPCs, other interfaces (e.g. RS232) and other data capturing devices.

User Interface
The user interface has to be available as a fat client (local installation) as well as a web client (web browser) with identical sets of functionality and feature. The web client muss has to run on Internet Explorer 9 and higher.

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4.5

System Architecture

System structure and landscape Concerning Installation topology the solution offers both: one centralized installation (all locations work on this single infrastructure) and the option to work with decentralized installations; in production one or the other topology approach will be deployed.

Application architecture The application architecture offers a 3 layer (data, logic, presentation) concept in a distributed system landscape. The layers are logically separated from each other. Virtualization is supported. The main focus is on the data and logic layer (hence application and database server). Preferred is ESX/VMware and optionally HyperV/MS.

Modular structure The solution comes with a modular structure. Hence the individual modules can be licensed, implemented, activated and used module by module.

Multi-tenancy The solution supports a multi-tenancy concept. Within a tenant several plants/sites can be managed / administered.

4.6

User/Account Management and Permissions concept

Active Directory Integration is required (Integrated Windows Authentication, IWA, and LDAP). Application permissions can be granularly assigned and administered with a role-based concept.

Security requirements / Role and Profile Definition Access to and permissions within the solution are controlled by a granular permissions concept and model which supports multiple detailed access groups and levels down to field level. User credentials (user ID and password) have to come from AD. Access for external (i.e. non-Ronal) parties (such as e.g. suppliers, customers) has to be possible. As for internals access (where) and permissions (what) can be granularly assigned by using groups and/or roles.

Workflow functionalities Availability of a flexible workflow engine that allows the dynamically define chains of activities for routing, escalation and other workflow purposes is key in order to automate recurring work items.

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4.7 Customizing/Personalization Capabilities The solution offers flexible and easy to use customization features. This comprises but is not limited to: Addition and deletion of predefined parameters, fields, views and filters and functionality (e.g. escalation, interfaces to databases and other applications) Changes per GUI or script and command line possible Configurable toolbar and menu for end user Dialog and functionality changes in application equally and automatically implemented in web interface (i.e. fat and web client are identical) System updates are without impact on content and implemented adaptations of configuration

Offline capabilities In case of network interrupts the solution has to continue to work in an offline mode.

Licensing The solution offers flexible and creative licensing options which cover Ronal requirements. In particular concurrent user licenses have to be supported.

Hotline The supplier has a central hotline. Communication languages are German and English. Any of the other mentioned Ronal languages is an asset. Operating hours have to be based on local time zones.

Languages The solution supports the following languages: German English Spanish Portuguese Italian Czech Polish Simplified Chinese

Additional languages are provided by the supplier or can be implemented/made available by means of simple translation tables or the like. The language versions of the user interface and the outputs (e.g. printing) can be separately managed and administered (example: users work with German user interface, the printouts are in English). The language can be selected on a per user basis. Printouts for external parties (e.g. for suppliers or customers) are printed in the supplier or customer language which is defined in the (supplier or customer) master data record.

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Implementation Concept
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Phase 1 (the pilot) will comprise the implementation of MES core features in the new Ronal plant W06 in Walbrzych/Poland which goes live on 1 April 2013. MES core functionality means those functionalities that are mandatory and absolutely required to run the production in the new plant. This set of functionality is referred to as priority A features

Functionality Scheduling of production orders Visualization of manufacturing situation and progress (scheduling), within a production day Controlling of production orders based on real time feedback (e.g. cycle times and scrap rates), within a production day Scheduling of change over on shop floor within a production day Allocation of operators / staff within a production day Wheel traceability Visualization of process parameters (real-time and history) Monitoring process parameter of machine status, manufacturing process, Monitoring of product quality Possibility to define warn limits for the process parameters and notification Access to PLC (control) Performance counter per employee (e.g. wage calculation) Reporting KPIs, e.g. OEE Production Report (monthly report) Daily production report Flexible reporting creation Energy consumption, GHG emission Maintenance Downtime Machine Life cycle of tools Administration of NC-Programs

Prio. W06 B B B C C C B B A B B B B C C C C C C C B

After this initial start and optimization phase of approx. 6 months will follow to stabilize the initial setup and to add additional (B and C) functionalities. Once W06 is stable (and as such the pilot is completed) MES is going to be rolled out plant after plant. The sequence and timing still has to be determined.

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