Manufacturing Execution Systems (MES)

Why MES ?
Anand Subramaniam

Highlights
Terms & Conceptual Overview Relationship & Data Flow - ERP, MES & CIM Why MES? Business Drivers / Benefits MES Components ISA 95 MES High Level Functionality System / Response Time MES Vendors
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Terms - ERP, MES & CIM

ERP systems handle financial functions, customer orders and send production requests to the factory floor. MES provide overall control and management of the factory floor, and provide updated information to ERP systems. The simplest model of CIM has MES as the middle ground between ERP systems and individual machine and automation controls
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Conceptual Overview
Relationship Management Transaction Systems Enterprise Management
Customer / Vendor / Employee Production Planning & Scheduling Enterprise Resource Planning

Manufacturing Execution Factory Systems Management Automation Process Asset Control and Control Optimisation

Enterprise Asset Management

Real-Time Systems

Process Measurement, Robotics Actuation, Energy Sensors Distribution & Meters

Motors & Drives Power Electronics Transformers

Switchgear
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Business Systems

Computer Integrated Manufacturing

Relationship - ERP & MES

Corporate
production planning, scheduling

MRP II/ ERP

batch, production run reporting or completion

Planning
l When/What to make l Planned/standard lead times/ yields/wastes/costs

Execution

Plant
recipes process setpoints operating instructions

l Production management/tracking - WIP, equipment, operators MES l Production scheduling , l Quality control/SQC actual process conditons l Costing completion of process steps l Maintenance and operations, performance of l Management functions equipment and raw material & Communications, reporting

operator actions

PLC

Robots/ AGV

Control
l l l l Ladder logic Continuous feedback PID Advanced control
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DCS

Data Flow ERP & MES

Planning
MPRII/ERP
Forecasting Costing Production Planning Product Definition Process Definition SOP Human Resources Inventory Management Purchasing Distribution
Product Demand BOM/Formula/Recipe/Drawing /Part Program Resources Routing/Process Labor Characteristics Inventory Status SOP, HEALTH, WORK Instructions

Execution
MES
Resource Alloc./Status Operations Scheduling Production Dispatching Document Control Data Collection/Acq. Labor Management WIP Status/Traceability Quality Management Performance Analysis Process Management Product Tracking and Genealogy Maintenance Management
Process Instructions: Recipes, Work Instructions, Part Programs, Order Specific, Machine Utilisation, Work Certification Requirements Operator Instructions: Scheduled (predictive) & Preventative Maintenance, Material Safety Instructions (documents), Machine Operation Instructions (documents) Drill Down (inquiries) Status Process Status Batch End Reports Ad Hoc Inquires Materials Analysis Events: Time/Date/Lot/Alarms Data Collected from Monitoring Functions: Process, Equipment, Environment, Labor, Material, Product Parameters

Control
Monitoring & Sensing
Process Equipment Environment Labor Material

Control
Machine Control Regulatory Control Realtime QC Advanced Process Controls

Order Status/COmpletions /Start-Due-End Resource Status/Usage Labor Status/Usage Material Status/Usage Actual BOM/Formula/Recipe/ Drawing/Part Program Actual Routing/Process Product Genealogy/Traceability /As Built Information Scrap/Waste

Operations
Process Sequencing Machine & Process Instructions Labor Instructions Human Machine Interfacing Safety Maintenance Focus: Process Decision Location: Shop Floor/Plant Floor

Focus: Customer Decision Location: Office

Focus: Product Decision Location: Factory

MESA International-White Paper

Why MES?
MES have evolved to fill the communication gap between the manufacturing planning system (MRP, ERP, etc.) and the control systems to run equipment on the plant floor. Co-ordinate functions on the shop floor to optimise the plant activities Provide visibility and flexibility to effectively manage supply chain

Business Drivers
Standard processes to enable benchmarking and best practices Seamless Integration Resource Utilisation Consistent Documentation Visibility of data globally Accurate and consistent measurement and reporting
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Benefits
Increases Operational Excellence Improves Asset Utilisation and the Management of Assets

Benefits as listed by Manufacturing Enterprise Solutions Association (http://www.mesa.org)

Reduces manufacturing cycle time Reduces or eliminated data Reduces work-in-process Reduces or eliminated paperwork between shifts Reduces lead times Improves product quality Eliminated lost paperwork Empowers plant operations people

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MES Components
Core
Material and Production Tracking Material Handling and Production Procedures Resource management and allocation Production Dispatching Data Collection

Extensions
Compliance Quality Assurance Performance Analysis Detail Scheduling Document Management Labor Management

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ISA 95
ISA = Instrumentation, Systems, and

Automation Society (ISA) Standard

Standard that defines how to link Enterprise systems with MES layer.

The MES Functionality The Data base schema at the MES Level The Messages between the Enterprise system and MES
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Business Functions
Enterprise Performance Reporting
Demand Planning Sales & Distribution Supply Chain Planning Material Management Production Planning Cost Accounting Warehouse Management Human Resource Management Maintenance Management

Level 4 Business Planning & Logistics

Manufacturing Execution Systems

Detail Scheduling Resource Management Process Optimisation Production Execution Recipe Management WIP Material Management Performance Management Production History Process Analysis Quality Management

Level 3 Manufacturing Operations

SCADA / PCS Systems

Real-Time Execution Real-Time Control Real-Time SPC Real-Time Monitoring

Level 2 Plant Floor Control

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MES Functionality
Dispatching and Production
Manages the flow of production in the form of jobs, orders, batches, lots and work orders by dispatching production to specific equipment and personnel. Includes information that is presented in the sequence in which the work needs to be done.

Quality Management

Provides real-time measurements collected form manufacturing to assure proper product quality control and to identify problems requiring attention. Includes SPC / SQC tracking and management of offline inspection operations

Data Collection & Acquisition

Obtains operational production and parametric data associated with production equipment and processes. Provides real-time statuses of production equipment and 15 processes

MES Functionality (Contd.)

Process Management
Monitors production and either automatically corrects or provides decision support to operators for correcting and improving inprocess functions. It may include alarm management to handle process deviations

Production Tracking & Genealogy

Provides status of production and disposition of work. Status information may include personnel, materials used, current production conditions. Includes recording of production information to allow forward and backward traceability.

Document Control

Control records and forms that must be maintained with the production unit. Includes work instructions, recipes, drawings, standard operating procedures (SOP), batch records, shift to shift communication. It sends instructions down to operations and device controls
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MES Functionality (Contd.)

Performance Analysis
Provides real-time reporting of actual manufacturing operations results along with comparisons to past history and expected results. Performance results include resource utilisation, resource availability, cycle time, conformance to schedule and standards. May include SPC / SQC analysis

Operational Detail Scheduling

Provides sequencing based on priorities, attributes, characteristics and production rules. It is finite and it recognises alternative and overlapping operations to calculate timing of equipment loading

Resource Allocation & Status

Manage the resources directly associated with control and manufacturing.

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MES Functionality (Contd.)

Labour Management
Provides status of personnel. Includes time and attendance, certification tracking, as well as preparation work as basis for activitybased costing. May interact with resource allocation for optimal assignments.

Maintenance Management

Functionality for maintaining equipment and tools. Ensures equipment and tools availability for manufacturing. May also include scheduling for periodic or preventive maintenance. Maintains history of past events to aid in diagnosing problems.
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System / Response Time

Planning Level ERP
(Enterprise Resource Planning)

Execution Level

MES
(Manufacturing Execution System)

SCADA

Supervisory Level
Control Level

(Supervisory Control and Data Acquisition)

DCS
(Distributed Control
System)

PLC
(Programmable Logic Controller)
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ms

seconds

hours

days

weeks

month

years

MES - Vendors
ABB Automation Technology Products (www.abb.com) GE Fanuc Automation (www.gefanuc.com) Honeywell Hi-Spec Solutions (www.hispec.com)

Kronos Inc (www.kronos.com)

RockwellSoftware (www.software.rockwell.com) Schneider Electric (/www.schneider-electric.com) Siemens Energy & Automation (www.sea.siemens.com) Tecnomatix Tecnologies (www.tecnomatix.com)
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Good Luck
http://www.linkedin.com/in/anandsubramaniam

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