Manufacturing Execution Systems

Manufacturing Execution Systems
Heiko Meyer Editor
Franz Fuchs Contributing Author
Klaus Thiel Contributing Author
Contents
Foreword xv
Acronyms xvii
1 Introduction . 1
1.1 Motivation 1
1.2 Aim of This Book 2
1.3 Structure of This Book 3
2 Factory of the Future 5
2.1 Historical Development of Manufacturing
Execution Systems . 5
2.1.1 Development of Business Data
Processing . 5
2.1.2 The Integration Concept: From
CIM to the Digital Factory . 6
2.2 Definitions of Terms . 8
2.2.1 Classification of Terms 8
2.2.2 Company Management Level 8
2.2.3 Production Management Level . 10
2.2.4 Control/Automation Level 13
2.3 Shortfalls of Existing Architectures and
Solutions . 13
2.3.1 Patchwork . 13
2.3.2 No Common Database 14
2.3.3 Excessive Response Times . 14
2.3.4 High Operating and Management
Outlay 15
2.4 Demands of Future Production Management
Systems 16
2.4.1 Target Management 16
2.4.2 Integration of Applications and Data . 18
2.4.3 Real-Time Data Management 21
2.4.4 Information Management . 24
2.4.5 Compliance Management . 25
2.4.6 Lean Sigma and MES . 27
2.5 Summary . 30
3 Concepts and Technologies 31
3.1 Commonalities between Existing Approaches
and MES . 31
viiviii C o n t e n t s
3.2 Norms and Guidelines . 31
3.2.1 ISA . 31
3.2.2 IEC . 35
3.2.3 VDI 36
3.2.4 FDA 36
3.2.5 NAMUR 37
3.3 Recommendations . 38
3.3.1 MESA . 38
3.3.2 VDA 39
3.3.3 VDMA 40
3.3.4 ZVEI . 40
3.4 Adjacent Areas 41
3.4.1 Historical Development of
ERP/PPS Systems 41
3.4.2 ERP/PPS Systems 41
3.4.3 Process Management Systems 42
3.4.4 SCADA Systems . 45
3.4.5 Simulation Systems . 45
3.5 Product Lifecycle Management 46
3.5.1 Historical Development . 46
3.5.2 Product Model . 47
3.5.3 Process Model . 48
3.5.4 Implementation Strategies . 48
3.5.5 Points of Contact with MES 49
3.6 Summary . 50
4 Core Function—Production Flow-Oriented
Design 53
4.1 Cross-System Cohesiveness 53
4.1.1 Classifi cation in the Overall System . 53
4.1.2 General and Complete Data Model . 54
4.1.3 Origins of Master Data 56
4.2 Data Model for Product Defi nition . 57
4.2.1 Relevant Concepts 57
4.2.2 The Operation . 59
4.2.3 The Work Plan . 63
4.2.4 The Parts List 66
4.2.5 Change Management and Product
History . 66
4.3 Data Model for Resource Management . 66
4.3.1 Description of Production
Environment . 66
4.3.2 Production Personnel . 71
4.3.3 Operating Resources 72
4.3.4 Materials and Preliminary Products . 73
4.3.5 Information and Documents . 74C o n t e n t s ix
4.4 System and Auxiliary Data 77
4.5 Order Fulfillment Data . 79
4.5.1 Orders 79
4.5.2 Production Data, Operating Data, and
Machine Data 79
4.5.3 Derived Performance Data and
Figures 81
4.6 Summary . 81
5 Core Function—Production Flow-Oriented
Planning 83
5.1 Integration within the Overall Process 83
5.2 Order Data Management . 83
5.3 Supply Management within the MES . 85
5.3.1 Demand Planning 85
5.3.2 Material Requirement Calculation . 86
5.3.3 Material Disposition in the MES or ERP
System 86
5.3.4 Incoming Goods . 87
5.3.5 Interaction between the ERP System
and the MES . 87
5.3.6 Material Warehousing Costs . 88
5.4 The Planning Process . 88
5.4.1 Planning Objectives 88
5.4.2 The “Updated” Work Plan: Condition
for Optimized Planning . 89
5.4.3 Work Scheduling . 89
5.4.4 Strategies for Sequence Planning and
Planning Algorithms 91
5.4.5 Forward Planning/Reverse Planning/
Bottleneck Planning 92
5.4.6 Collision-Free Planning of a Time
Container . 93
5.4.7 Setup Optimization and Warehousing
Costs . 94
5.5 The Importance of the Control Station 94
5.5.1 Core Elements . 94
5.5.2 User Interface 95
5.6 Personnel Planning and Release of Orders . 96
5.7 Summary . 97
6 Core Function—Order Processing 99
6.1 General Information on Order Processing . 99
6.1.1 Classification within the Overall
System 996.1.2 Functions of Order Fulfi llment . 99
6.1.3 The MES Terminal 100
6.2 Order Preparation and Setup 103
6.2.1 Changing Tools 103
6.2.2 Machine Settings . 104
6.2.3 Material Provision 105
6.2.4 Test Run 105
6.3 Order Control . 106
6.3.1 Information Management . 106
6.3.2 Control and Tracing of Production
Units . 106
6.3.3 Managing the Production Bin 106
6.3.4 Material Flow Control 106
6.3.5 Order Processing and Operating Data
Recording . 109
6.3.6 Process and Quality Assurance . 110
6.4 Performance Data . 112
6.4.1 Involved Departments 112
6.4.2 Key Figures and Performance
Record 116
6.4.3 Ongoing Analysis and Evaluations . 116
6.4.4 More Long-Term Analyses and
Evaluations 117
6.5 Maintenance Management 118
6.5.1 Tasks . 118
6.5.2 Preventive Maintenance and Repair . 118
6.5.3 Alarm Management 119
6.6 Summary . 119
7 Technical Aspects 121
7.1 Software Architecture 121
7.1.1 Fundamental Variants 121
7.1.2 Overview of Central Components . 122
7.1.3 Platform Independence . 124
7.1.4 Scalability . 125
7.1.5 Flexible Adjustment versus
Suitability for Updates 127
7.1.6 MES and Service-Oriented
Architecture (SOA) . 129
7.2 Database . 130
7.2.1 Introduction . 130
7.2.2 Resource Monitoring . 130
7.2.3 Scaling the Database System 132
7.2.4 Data Management and Archiving . 133
7.2.5 Running Maintenance 134
x C o n t e n t s7.3 Interfaces with Other IT Systems 134
7.3.1 Overview . 134
7.3.2 Interface with Production . 134
7.3.3 Interface with an ERP System 140
7.3.4 Interface with the IT Infrastructure . 143
7.3.5 Interface with Communication
Systems . 144
7.3.6 Other Interfaces 144
7.4 User Interfaces 144
7.4.1 Usage and Visualization . 144
7.4.2 Reporting . 148
7.4.3 Automated Information Distribution . 150
7.5 Summary . 151
8 Evaluation of the Cost-Effectiveness of MES 153
8.1 General Information on Cost-Effectiveness . 153
8.1.1 Calculation of Cost-Effectiveness . 153
8.1.2 Comparative Cost Method . 154
8.1.3 Value-Benefit Analysis 154
8.1.4 Performance Measurement 155
8.1.5 Total Cost of Ownership . 155
8.2 General Information on Evaluation 156
8.2.1 Assessing Cost-Effectiveness in
Practice . 156
8.2.2 Rationalization Measures in
Production 157
8.2.3 MES for Reducing Sources of Loss . 160
8.3 The Benefits of an MES . 161
8.3.1 Integrated Data Transparency 161
8.3.2 Reducing Time Usage . 162
8.3.3 Reducing Administration Expenses . 165
8.3.4 Improved Customer Service . 166
8.3.5 Improved Quality 166
8.3.6 Early Warning System, Real-Time Cost
Control . 167
8.3.7 Increasing Employee Productivity . 167
8.3.8 Compliance with Directives . 168
8.4 The Costs of an MES . 168
8.5 Summary . 169
9 Implementing an MES in Production . 171
9.1 Implementing IT Systems in General 171
9.1.1 Selection of Components 171
9.1.2 Implementation Strategies . 173
9.1.3 Problems during Implementation . 174
C o n t e n t s xi9.2 Preparation of the Implementation Project . 176
9.2.1 Establishing the Core Team 176
9.2.2 The Fundamental Decision: MES:
Yes or No 177
9.2.3 Establishing the Project Team 177
9.3 Analysis of the Actual Situation . 178
9.3.1 Introduction . 178
9.3.2 Existing Infrastructure 179
9.3.3 Existing Processes and Required
Functions 180
9.3.4 Key Figures as the Basis for Monitoring
Success . 181
9.3.5 Suitable Key Figures for Success
Monitoring 182
9.3.6 Other Factors for Success 184
9.4 Creation of a Project Plan . 185
9.5 Contract Specifications . 186
9.6 Selection of a Suitable System . 187
9.6.1 Market Situation . 187
9.6.2 Short-Listing and Limiting to
Two or Three Applicants 187
9.6.3 Detailed Analysis of the Favorites and
Decision 189
9.7 Implementation Process 191
9.7.1 Project Management 191
9.7.2 Training Management . 192
9.7.3 Operating Concept . 193
9.8 Summary . 195
10 Examples for Application . 197
10.1 Mixed Processes . 197
10.2 Sensient Technologies: Emulsions 198
10.2.1 Information on Sensient Technologies
Corporation 198
10.2.2 Description of the Production
Process 198
10.2.3 Basic Quantity Units and
Production Units . 200
10.2.4 Production Process Plan . 200
10.2.5 Challenges for the MES 200
10.2.6 Realization and Implementation 204
10.3 Acker: Synthetic Fiber Fabrics . 204
10.3.1 Information on the Company 204
10.3.2 Description of the Production
Process 204
xii C o n t e n t s10.3.3 Basic Quantity Units and Production
Units 209
10.3.4 Production Flow Plan . 210
10.3.5 Tasks of the MES . 210
10.3.6 Challenges . 212
10.3.7 Realization and Implementation 213
10.4 Summary . 214
11 Visions 215
11.1 Merging the Systems . 215
11.2 The MES as a Medium of Product-Development
Management . 217
11.2.1 Phases of Product Development 217
11.2.2 Request Handling 217
11.2.3 Concept Documentation and
Designing Requirements 218
11.2.4 Construction of the Product 219
11.2.5 Computer-Aided Flow Planning 220
11.2.6 Production Management 221
11.3 Standardization of Function Modules 221
11.4 Merging Consultancy Activities and
IT Systems . 221
11.5 Summary . 222
12 Summary of the Book . 223
References . 227
Glossary . 229
Index
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