Manufacturing Execution

Systems (MES)

Why MES ?

Anand Subramaniam

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 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
Customer / Vendor / Employee
Management
Production Enterprise
Enterprise Planning & Resource
Transaction
Management Scheduling Planning Enterprise
Systems
Asset
Factory Manufacturing Execution Management
Management Systems

Automation Process Asset

and Control Control Optimisation
Real-Time Process
Systems
Measurement, Robotics Motors &
Transformers
Drives
Actuation,
Energy
Sensors Power
Distribution Switchgear
& Meters Electronics 4
Business Systems

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Computer Integrated Manufacturing

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 Relationship - ERP & MES
MRP II/ Planning
Corporate ERP  When/What to make
 Planned/standard lead times/
batch, yields/wastes/costs
production planning, production run
scheduling reporting or
completion Execution
 Production management/tracking
- WIP, equipment, operators
Plant MES
 Production scheduling
,  Quality control/SQC
actual process conditons  Costing
recipes
process setpoints completion of process steps  Maintenance
operating instructions and operations, performance of  Management functions -
equipment and raw material & Communications, reporting
operator actions
Robots/ Control
PLC  Ladder logic
AGV
 Continuous feedback
 PID
 Advanced control
DCS 7
 Data Flow – ERP & MES
Planning Execution Control
Process Instructions: Recipes,
MPRII/ERP MES Work Instructions, Part Programs,
Monitoring & Sensing
Product Demand Process
Order Specific, Machine
BOM/Formula/Recipe/Drawing
Forecasting Resource Alloc./Status Utilisation, Work Certification Equipment
/Part Program
Costing Resources Operations Scheduling
Requirements Environment
Operator Instructions: Scheduled
Production Planning Routing/Process
Production Dispatching Labor
(predictive) & Preventative
Product Definition
Labor Characteristics
Document Control Maintenance, Material
Inventory Status
Process Definition SOP, HEALTH, WORK Instructions Data Collection/Acq. Material Safety Instructions Control
(documents), Machine Operation
SOP Labor Management Machine Control
Instructions (documents)
Human Resources WIP Status/Traceability Regulatory Control
Inventory Management Order Status/COmpletions Quality Management Drill Down (inquiries) Status Realtime QC
/Start-Due-End Process Status
Purchasing Performance Analysis Advanced Process Controls
Resource Status/Usage Batch End Reports
Distribution Labor Status/Usage Process Management Operations
Material Status/Usage Product Tracking Ad Hoc Inquires Process Sequencing
Actual BOM/Formula/Recipe/ and Genealogy Materials Analysis Machine & Process Instructions
Drawing/Part Program Events: Time/Date/Lot/Alarms
Maintenance Labor Instructions
Actual Routing/Process Data Collected from Monitoring
Product Genealogy/Traceability Management Human Machine Interfacing
Functions: Process, Equipment,
/As Built Information Environment, Labor, Material, Product Safety
Scrap/Waste Parameters Maintenance

Focus: Focus: Focus:

Customer Product Process
Decision Location: Decision Location: Decision Location:
Office Factory Shop Floor/Plant Floor

MESA International-White Paper

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 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 9
 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 11
 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 12
 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
Level 4
Demand Cost Human Resource
Planning
Supply Chain Planning
Accounting Management Business
Planning &
Sales & Material Production Warehouse Maintenance
Distribution Management Planning Management Management
Logistics

Manufacturing Execution Systems

Detail Process Recipe Performance Process

Scheduling Optimisation Management Management Analysis Level 3
Manufacturing
Resource Production WIP Material Production Quality Operations
Management Execution Management History Management

SCADA / PCS Systems

Real-Time Real-Time
Execution SPC
Level 2
Plant Floor
Real-Time Real-Time
Control Monitoring
Control 14
 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
processes 15
 MES Functionality (Contd.)
Process Management
– Monitors production and either automatically corrects or provides
decision support to operators for correcting and improving in-
process 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 activity–based
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
ERP
Level (Enterprise Resource Planning)

MES
Execution (Manufacturing Execution System)
Level
SCADA
(Supervisory Control and Data
Supervisory Acquisition)
Level
DCS
(Distributed Control
System)
Control
Level 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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