You are previewing Manufacturing Execution Systems (MES): Optimal Design, Planning, and Deployment.
O'Reilly logo
Manufacturing Execution Systems (MES): Optimal Design, Planning, and Deployment

Book Description

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, Gainesville Streamline 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.

Table of Contents

  1. Cover Page
  2. Manufacturing Execution Systems
  3. Copyright Page
  4. Contents
  5. Foreword
  6. Acronyms
  7. 1 Introduction
    1. 1.1 Motivation
    2. 1.2 Aim of This Book
    3. 1.3 Structure of This Book
  8. 2 Factory of the Future
    1. 2.1 Historical Development of Manufacturing Execution Systems
      1. 2.1.1 Development of Business Data Processing
      2. 2.1.2 The Integration Concept: From CIM to the Digital Factory
    2. 2.2 Definitions of Terms
      1. 2.2.1 Classification of Terms
      2. 2.2.2 Company Management Level
      3. 2.2.3 Production Management Level
      4. 2.2.4 Control/Automation Level
    3. 2.3 Shortfalls of Existing Architectures and Solutions
      1. 2.3.1 Patchwork
      2. 2.3.2 No Common Database
      3. 2.3.3 Excessive Response Times
      4. 2.3.4 High Operating and Management Outlay
    4. 2.4 Demands of Future Production Management Systems
      1. 2.4.1 Target Management
      2. 2.4.2 Integration of Applications and Data
      3. 2.4.3 Real-Time Data Management
      4. 2.4.4 Information Management
      5. 2.4.5 Compliance Management
      6. 2.4.6 Lean Sigma and MES
    5. 2.5 Summary
  9. 3 Concepts and Technologies
    1. 3.1 Commonalities between Existing Approaches and MES
    2. 3.2 Norms and Guidelines
      1. 3.2.1 ISA
      2. 3.2.2 IEC
      3. 3.2.3 VDI
      4. 3.2.4 FDA
      5. 3.2.5 NAMUR
    3. 3.3 Recommendations
      1. 3.3.1 MESA
      2. 3.3.2 VDA
      3. 3.3.3 VDMA
      4. 3.3.4 ZVEI
    4. 3.4 Adjacent Areas
      1. 3.4.1 Historical Development of ERP/PPS Systems
      2. 3.4.2 ERP/PPS Systems
      3. 3.4.3 Process Management Systems
      4. 3.4.4 SCADA Systems
      5. 3.4.5 Simulation Systems
    5. 3.5 Product Lifecycle Management
      1. 3.5.1 Historical Development
      2. 3.5.2 Product Model
      3. 3.5.3 Process Model
      4. 3.5.4 Implementation Strategies
      5. 3.5.5 Points of Contact with MES
    6. 3.6 Summary
  10. 4 Core Function—Production Flow-Oriented Design
    1. 4.1 Cross-System Cohesiveness
      1. 4.1.1 Classification in the Overall System
      2. 4.1.2 General and Complete Data Model
      3. 4.1.3 Origins of Master Data
    2. 4.2 Data Model for Product Definition
      1. 4.2.1 Relevant Concepts
      2. 4.2.2 The Operation
      3. 4.2.3 The Work Plan
      4. 4.2.4 The Parts List
      5. 4.2.5 Change Management and Product History
    3. 4.3 Data Model for Resource Management
      1. 4.3.1 Description of Production Environment
      2. 4.3.2 Production Personnel
      3. 4.3.3 Operating Resources
      4. 4.3.4 Materials and Preliminary Products
      5. 4.3.5 Information and Documents
    4. 4.4 System and Auxiliary Data
    5. 4.5 Order Fulfillment Data
      1. 4.5.1 Orders
      2. 4.5.2 Production Data, Operating Data, and Machine Data
      3. 4.5.3 Derived Performance Data and Figures
    6. 4.6 Summary
  11. 5 Core Function—Production Flow-Oriented Planning
    1. 5.1 Integration within the Overall Process
    2. 5.2 Order Data Management
    3. 5.3 Supply Management within the MES
      1. 5.3.1 Demand Planning
      2. 5.3.2 Material Requirement Calculation
      3. 5.3.3 Material Disposition in the MES or ERP System
      4. 5.3.4 Incoming Goods
      5. 5.3.5 Interaction between the ERP System and the MES
      6. 5.3.6 Material Warehousing Costs
    4. 5.4 The Planning Process
      1. 5.4.1 Planning Objectives
      2. 5.4.2 The “Updated” Work Plan: Condition for Optimized Planning
      3. 5.4.3 Work Scheduling
      4. 5.4.4 Strategies for Sequence Planning and Planning Algorithms
      5. 5.4.5 Forward Planning/Reverse Planning/Bottleneck Planning
      6. 5.4.6 Collision-Free Planning of a Time Container
      7. 5.4.7 Setup Optimization and Warehousing Costs
    5. 5.5 The Importance of the Control Station
      1. 5.5.1 Core Elements
      2. 5.5.2 User Interface
    6. 5.6 Personnel Planning and Release of Orders
    7. 5.7 Summary
  12. 6 Core Function—Order Processing
    1. 6.1 General Information on Order Processing
      1. 6.1.1 Classification within the Overall System
      2. 6.1.2 Functions of Order Fulfillment
      3. 6.1.3 The MES Terminal
    2. 6.2 Order Preparation and Setup
      1. 6.2.1 Changing Tools
      2. 6.2.2 Machine Settings
      3. 6.2.3 Material Provision
      4. 6.2.4 Test Run
    3. 6.3 Order Control
      1. 6.3.1 Information Management
      2. 6.3.2 Control and Tracing of Production Units
      3. 6.3.3 Managing the Production Bin
      4. 6.3.4 Material Flow Control
      5. 6.3.5 Order Processing and Operating Data Recording
      6. 6.3.6 Process and Quality Assurance
    4. 6.4 Performance Data
      1. 6.4.1 Involved Departments
      2. 6.4.2 Key Figures and Performance Record
      3. 6.4.3 Ongoing Analysis and Evaluations
      4. 6.4.4 More Long-Term Analyses and Evaluations
    5. 6.5 Maintenance Management
      1. 6.5.1 Tasks
      2. 6.5.2 Preventive Maintenance and Repair
      3. 6.5.3 Alarm Management
    6. 6.6 Summary
  13. 7 Technical Aspects
    1. 7.1 Software Architecture
      1. 7.1.1 Fundamental Variants
      2. 7.1.2 Overview of Central Components
      3. 7.1.3 Platform Independence
      4. 7.1.4 Scalability
      5. 7.1.5 Flexible Adjustment versus Suitability for Updates
      6. 7.1.6 MES and Service-Oriented Architecture (SOA)
    2. 7.2 Database
      1. 7.2.1 Introduction
      2. 7.2.2 Resource Monitoring
      3. 7.2.3 Scaling the Database System
      4. 7.2.4 Data Management and Archiving
      5. 7.2.5 Running Maintenance
    3. 7.3 Interfaces with Other IT Systems
      1. 7.3.1 Overview
      2. 7.3.2 Interface with Production
      3. 7.3.3 Interface with an ERP System
      4. 7.3.4 Interface with the IT Infrastructure
      5. 7.3.5 Interface with Communication Systems
      6. 7.3.6 Other Interfaces
    4. 7.4 User Interfaces
      1. 7.4.1 Usage and Visualization
      2. 7.4.2 Reporting
      3. 7.4.3 Automated Information Distribution
    5. 7.5 Summary
  14. 8 Evaluation of the Cost-Effectiveness of MES
    1. 8.1 General Information on Cost-Effectiveness
      1. 8.1.1 Calculation of Cost-Effectiveness
      2. 8.1.2 Comparative Cost Method
      3. 8.1.3 Value-Benefit Analysis
      4. 8.1.4 Performance Measurement
      5. 8.1.5 Total Cost of Ownership
    2. 8.2 General Information on Evaluation
      1. 8.2.1 Assessing Cost-Effectiveness in Practice
      2. 8.2.2 Rationalization Measures in Production
      3. 8.2.3 MES for Reducing Sources of Loss
    3. 8.3 The Benefits of an MES
      1. 8.3.1 Integrated Data Transparency
      2. 8.3.2 Reducing Time Usage
      3. 8.3.3 Reducing Administration Expenses
      4. 8.3.4 Improved Customer Service
      5. 8.3.5 Improved Quality
      6. 8.3.6 Early Warning System, Real-Time Cost Control
      7. 8.3.7 Increasing Employee Productivity
      8. 8.3.8 Compliance with Directives
    4. 8.4 The Costs of an MES
    5. 8.5 Summary
  15. 9 Implementing an MES in Production
    1. 9.1 Implementing IT Systems in General
      1. 9.1.1 Selection of Components
      2. 9.1.2 Implementation Strategies
      3. 9.1.3 Problems during Implementation
    2. 9.2 Preparation of the Implementation Project
      1. 9.2.1 Establishing the Core Team
      2. 9.2.2 The Fundamental Decision: MES: Yes or No
      3. 9.2.3 Establishing the Project Team
    3. 9.3 Analysis of the Actual Situation
      1. 9.3.1 Introduction
      2. 9.3.2 Existing Infrastructure
      3. 9.3.3 Existing Processes and Required Functions
      4. 9.3.4 Key Figures as the Basis for Monitoring Success
      5. 9.3.5 Suitable Key Figures for Success Monitoring
      6. 9.3.6 Other Factors for Success
    4. 9.4 Creation of a Project Plan
    5. 9.5 Contract Specifications
    6. 9.6 Selection of a Suitable System
      1. 9.6.1 Market Situation
      2. 9.6.2 Short-Listing and Limiting to Two or Three Applicants
      3. 9.6.3 Detailed Analysis of the Favorites and Decision
    7. 9.7 Implementation Process
      1. 9.7.1 Project Management
      2. 9.7.2 Training Management
      3. 9.7.3 Operating Concept
    8. 9.8 Summary
  16. 10 Examples for Application
    1. 10.1 Mixed Processes
    2. 10.2 Sensient Technologies: Emulsions
      1. 10.2.1 Information on Sensient Technologies Corporation
      2. 10.2.2 Description of the Production Process
      3. 10.2.3 Basic Quantity Units and Production Units
      4. 10.2.4 Production Process Plan
      5. 10.2.5 Challenges for the MES
      6. 10.2.6 Realization and Implementation
    3. 10.3 Acker: Synthetic Fiber Fabrics
      1. 10.3.1 Information on the Company
      2. 10.3.2 Description of the Production Process
      3. 10.3.3 Basic Quantity Units and Production Units
      4. 10.3.4 Production Flow Plan
      5. 10.3.5 Tasks of the MES
      6. 10.3.6 Challenges
      7. 10.3.7 Realization and Implementation
    4. 10.4 Summary
  17. 11 Visions
    1. 11.1 Merging the Systems
    2. 11.2 The MES as a Medium of Product-Development Management
      1. 11.2.1 Phases of Product Development
      2. 11.2.2 Request Handling
      3. 11.2.3 Concept Documentation and Designing Requirements
      4. 11.2.4 Construction of the Product
      5. 11.2.5 Computer-Aided Flow Planning
      6. 11.2.6 Production Management
    3. 11.3 Standardization of Function Modules
    4. 11.4 Merging Consultancy Activities and IT Systems
    5. 11.5 Summary
  18. 12 Summary of the Book
  19. References
  20. Glossary
  21. Index