Manufacturing Execution Systems (MES): Optimal Design, Planning, and Deployment

by Meyer, Heiko; Fuchs, Franz; Thiel, Klaus

• ISBN13: 9780071623834
• ISBN10: 0071623833
• Edition: 1st
• Format: Hardcover
• Copyright: 2009-03-23
• Publisher: McGraw-Hill Education

Summary

Implement Enterprise-Wide Manufacturing Execution Systems Solutions"The clearest exposition I have seen of the ideal anatomy of a production-oriented IT system. ...Palatable to decision makers within an organization...IT professionals [and] academics in IT and operations management. ...Useful and interesting." --From the Foreword by Dr. Anand Paul, Associate Professor, Department of Information Systems and Operations Management, Warrington College of Business Administration, University of Florida, GainesvilleStreamline the production process from top-tier management to the plant floor using cutting-edge MES tools and techniques. Manufacturing Execution Systems shows, step-by-step, how to select hardware and software, develop implementation plans, and maintain an integrated MES solution across your entire enterprise. Learn how to maximize process capability, generate manufacturing intelligence, handle order fulfillment and QA, and ensure optimal ROI. This practical guide includes real-world case studies, predictions for the future of production-oriented IT systems, and detailed technical appendices. Understand and apply MES, CPM, and integration concepts Analyze and assess the advantages of different MES solutions Dynamically map and model your facility, from supply chain to output Manage plant data, business information, and standards compliance Increase production efficiency using TQM and Lean techniques Carry out production flow-oriented design and sequence planning Govern order fulfillment, quality control, and plant maintenance Incorporate human resources, ERP, and product lifecycle information

Author Biography

Heiko Meyer is a professor at the University of Applied Science in Munich. He also collaborates with Gefasoft Inc., in the creation of MES software.

Table of Contents

Foreword	p. xv
Acronyms	p. xvii
Introduction	p. 1
Motivation	p. 1
Aim of This Book	p. 2
Structure of This Book	p. 3
Factory of the Future	p. 5
Historical Development of Manufacturing Execution Systems	p. 5
Development of Business Data Processing	p. 5
The Integration Concept: From CIM to the Digital Factory	p. 6
Definitions of Terms	p. 8
Classification of Terms	p. 8
Company Management Level	p. 8
Production Management Level	p. 10
Control/Automation Level	p. 13
Shortfalls of Existing Architectures and Solutions	p. 13
Patchwork	p. 13
No Common Database	p. 14
Excessive Response Times	p. 14
High Operating and Management Outlay	p. 15
Demands of Future Production Management Systems	p. 16
Target Management	p. 16
Integration of Applications and Data	p. 18
Real-Time Data Management	p. 21
Information Management	p. 24
Compliance Management	p. 25
Lean Sigma and MES	p. 27
Summary	p. 30
Concepts and Technologies	p. 31
Commonalities between Existing Approaches and MES	p. 31
Norms and Guidelines	p. 31
ISA	p. 31
IEC	p. 35
VDI	p. 36
FDA	p. 36
NAMUR	p. 37
Recommendations	p. 38
MESA	p. 38
VDA	p. 39
VDMA	p. 40
ZVEI	p. 40
Adjacent Areas	p. 41
Historical Development of ERP/PPS Systems	p. 41
ERP/PPS Systems	p. 41
Process Management Systems	p. 42
Scada Systems	p. 45
Simulation Systems	p. 45
Product Lifecycle Management	p. 46
Historical Development	p. 46
Product Model	p. 47
Process Model	p. 48
Implementation Strategies	p. 48
Points of Contact with MES	p. 49
Summary	p. 50
Core Function-Production Flow-Oriented Design	p. 53
Cross-System Cohesiveness	p. 53
Classification in the Overall System	p. 53
General and Complete Data Model	p. 54
Origins of Master Data	p. 56
Data Model for Product Definition	p. 57
Relevant Concepts	p. 57
The Operation	p. 59
The Work Plan	p. 63
The Parts List	p. 66
Change Management and Product History	p. 66
Data Model for Resource Management	p. 66
Description of Production Environment	p. 66
Production Personnel	p. 71
Operating Resources	p. 72
Materials and Preliminary Products	p. 73
Information and Documents	p. 74
System and Auxiliary Data	p. 77
Order Fulfillment Data	p. 79
Orders	p. 79
Production Data, Operating Data, and Machine Data	p. 79
Derived Performance Data and Figures	p. 81
Summary	p. 81
Core Function-Production Flow-Oriented Planning	p. 83
Integration within the Overall Process	p. 83
Order Data Management	p. 83
Supply Management within the MES	p. 85
Demand Planning	p. 85
Material Requirement Calculation	p. 86
Material Disposition in the MES or ERP System	p. 86
Incoming Goods	p. 87
Interaction between the ERP System and the MES	p. 87
Material Warehousing Costs	p. 88
The Planning Process	p. 88
Planning Objectives	p. 88
The "Updated" Work Plan: Condition for Optimized Planning	p. 89
Work Scheduling	p. 89
Strategies for Sequence Planning and Planning Algorithms	p. 91
Forward Planning/Reverse Planning/Bottleneck Planning	p. 92
Collision-Free Planning of a Time Container	p. 93
Setup Optimization and Warehousing Costs	p. 94
The Importance of the Control Station	p. 94
Core Elements	p. 94
User Interface	p. 95
Personnel Planning and Release of Orders	p. 96
Summary	p. 97
Core Function-Order Processing	p. 99
General Information on Order Processing	p. 99
Classification within the Overall System	p. 99
Functions of Order Fulfillment	p. 99
The MES Terminal	p. 100
Order Preparation and Setup	p. 103
Changing Tools	p. 103
Machine Settings	p. 104
Material Provision	p. 105
Test Run	p. 105
Order Control	p. 106
Information Management	p. 106
Control and Tracing of Production Units	p. 106
Managing the Production Bin	p. 106
Material Flow Control	p. 106
Order Processing and Operating Data Recording	p. 109
Process and Quality Assurance	p. 110
Performance Data	p. 112
Involved Departments	p. 112
Key Figures and Performance Record	p. 116
Ongoing Analysis and Evaluations	p. 116
More Long-Term Analyses and Evaluations	p. 117
Maintenance Management	p. 118
Tasks	p. 118
Preventive Maintenance and Repair	p. 118
Alarm Management	p. 119
Summary	p. 119
Technical Aspects	p. 121
Software Architecture	p. 121
Fundamental Variants	p. 121
Overview of Central Components	p. 122
Platform Independence	p. 124
Scalability	p. 125
Flexible Adjustment versus Suitability for Updates	p. 127
MES and Service-Oriented Architecture (SOA)	p. 129
Database	p. 130
Introduction	p. 130
Resource Monitoring	p. 130
Scaling the Database System	p. 132
Data Management and Archiving	p. 133
Running Maintenance	p. 134
Interfaces with Other IT Systems	p. 134
Overview	p. 134
Interface with Production	p. 134
Interface with an ERP System	p. 140
Interface with the IT Infrastructure	p. 143
Interface with Communication Systems	p. 144
Other Interfaces	p. 144
User Interfaces	p. 144
Usage and Visualization	p. 144
Reporting	p. 148
Automated Information Distribution	p. 150
Summary	p. 151
Evaluation of the Cost-Effectiveness of Mes	p. 153
General Information on Cost-Effectiveness	p. 153
Calculation of Cost-Effectiveness	p. 153
Comparative Cost Method	p. 154
Value-Benefit Analysis	p. 154
Performance Measurement	p. 155
Total Cost of Ownership	p. 155
General Information on Evaluation	p. 156
Assessing Cost-Effectiveness in Practice	p. 156
Rationalization Measures in Production	p. 157
MES for Reducing Sources of Loss	p. 160
The Benefits of an MES	p. 161
Integrated Data Transparency	p. 161
Reducing Time Usage	p. 162
Reducing Administration Expenses	p. 165
Improved Customer Service	p. 166
Improved Quality	p. 166
Early Warning System, Real-Time Cost Control	p. 167
Increasing Employee Productivity	p. 167
Compliance with Directives	p. 168
The Costs of an MES	p. 168
Summary	p. 169
Implementing an MES in Production	p. 171
Implementing IT Systems in General	p. 171
Selection of Components	p. 171
Implementation Strategies	p. 173
Problems during Implementation	p. 174
Preparation of the Implementation Project	p. 176
Establishing the Core Team	p. 176
The Fundamental Decision: MES: Yes or No	p. 177
Establishing the Project Team	p. 177
Analysis of the Actual Situation	p. 178
Introduction	p. 178
Existing Infrastructure	p. 179
Existing Processes and Required Functions	p. 180
Key Figures as the Basis for Monitoring Success	p. 181
Suitable Key Figures for Success Monitoring	p. 182
Other Factors for Success	p. 184
Creation of a Project Plan	p. 185
Contract Specifications	p. 186
Selection of a Suitable System	p. 187
Market Situation	p. 187
Short-Listing and Limiting to Two or Three Applicants	p. 187
Detailed Analysis of the Favorites and Decision	p. 189
Implementation Process	p. 191
Project Management	p. 191
Training Management	p. 192
Operating Concept	p. 193
Summary	p. 195
Examples for Application	p. 197
Mixed Processes	p. 197
Sensient Technologies: Emulsions	p. 198
Information on Sensient Technologies Corporation	p. 198
Description of the Production Process	p. 198
Basic Quantity Units and Production Units	p. 200
Production Process Plan	p. 200
Challenges for the MES	p. 200
Realization and Implementation	p. 204
Acker: Synthetic Fiber Fabrics	p. 204
Information on the Company	p. 204
Description of the Production Process	p. 204
Basic Quantity Units and Production Units	p. 209
Production Flow Plan	p. 210
Tasks of the MES	p. 210
Challenges	p. 212
Realization and Implementation	p. 213
Summary	p. 214
Visions	p. 215
Merging the Systems	p. 215
The MES as a Medium of Product-Development Management	p. 217
Phases of Product Development	p. 217
Request Handling	p. 217
Concept Documentation and Designing Requirements	p. 218
Construction of the Product	p. 219
Computer-Aided Flow Planning	p. 220
Production Management	p. 221
Standardization of Function Modules	p. 221
Merging Consultancy Activities and IT Systems	p. 221
Summary	p. 222
Summary of the Book	p. 223
References	p. 227
Glossary	p. 229
Index	p. 245
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