book

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

by Heiko Meyer, Franz Fuchs, Klaus Thiel

April 2009

Intermediate to advanced

272 pages

7h 22m

English

McGraw-Hill

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Cover Page
Manufacturing Execution Systems
Copyright Page
Contents
Foreword
Acronyms
1 Introduction
1.1 Motivation1.2 Aim of This Book1.3 Structure of This Book
2 Factory of the Future
2.1 Historical Development of Manufacturing Execution Systems2.1.1 Development of Business Data Processing2.1.2 The Integration Concept: From CIM to the Digital Factory2.2 Definitions of Terms2.2.1 Classification of Terms2.2.2 Company Management Level2.2.3 Production Management Level2.2.4 Control/Automation Level2.3 Shortfalls of Existing Architectures and Solutions2.3.1 Patchwork2.3.2 No Common Database2.3.3 Excessive Response Times2.3.4 High Operating and Management Outlay2.4 Demands of Future Production Management Systems2.4.1 Target Management2.4.2 Integration of Applications and Data2.4.3 Real-Time Data Management2.4.4 Information Management2.4.5 Compliance Management2.4.6 Lean Sigma and MES2.5 Summary
3 Concepts and Technologies
3.1 Commonalities between Existing Approaches and MES3.2 Norms and Guidelines3.2.1 ISA3.2.2 IEC3.2.3 VDI3.2.4 FDA3.2.5 NAMUR3.3 Recommendations3.3.1 MESA3.3.2 VDA3.3.3 VDMA3.3.4 ZVEI3.4 Adjacent Areas3.4.1 Historical Development of ERP/PPS Systems3.4.2 ERP/PPS Systems3.4.3 Process Management Systems3.4.4 SCADA Systems3.4.5 Simulation Systems3.5 Product Lifecycle Management3.5.1 Historical Development3.5.2 Product Model3.5.3 Process Model3.5.4 Implementation Strategies3.5.5 Points of Contact with MES3.6 Summary
4 Core Function—Production Flow-Oriented Design
4.1 Cross-System Cohesiveness4.1.1 Classification in the Overall System4.1.2 General and Complete Data Model4.1.3 Origins of Master Data4.2 Data Model for Product Definition4.2.1 Relevant Concepts4.2.2 The Operation4.2.3 The Work Plan4.2.4 The Parts List4.2.5 Change Management and Product History4.3 Data Model for Resource Management4.3.1 Description of Production Environment4.3.2 Production Personnel4.3.3 Operating Resources4.3.4 Materials and Preliminary Products4.3.5 Information and Documents4.4 System and Auxiliary Data4.5 Order Fulfillment Data4.5.1 Orders4.5.2 Production Data, Operating Data, and Machine Data4.5.3 Derived Performance Data and Figures4.6 Summary

5 Core Function—Production Flow-Oriented Planning
5.1 Integration within the Overall Process5.2 Order Data Management5.3 Supply Management within the MES5.3.1 Demand Planning5.3.2 Material Requirement Calculation5.3.3 Material Disposition in the MES or ERP System5.3.4 Incoming Goods5.3.5 Interaction between the ERP System and the MES5.3.6 Material Warehousing Costs5.4 The Planning Process5.4.1 Planning Objectives5.4.2 The “Updated” Work Plan: Condition for Optimized Planning5.4.3 Work Scheduling5.4.4 Strategies for Sequence Planning and Planning Algorithms5.4.5 Forward Planning/Reverse Planning/Bottleneck Planning5.4.6 Collision-Free Planning of a Time Container5.4.7 Setup Optimization and Warehousing Costs5.5 The Importance of the Control Station5.5.1 Core Elements5.5.2 User Interface5.6 Personnel Planning and Release of Orders5.7 Summary
6 Core Function—Order Processing
6.1 General Information on Order Processing6.1.1 Classification within the Overall System6.1.2 Functions of Order Fulfillment6.1.3 The MES Terminal6.2 Order Preparation and Setup6.2.1 Changing Tools6.2.2 Machine Settings6.2.3 Material Provision6.2.4 Test Run6.3 Order Control6.3.1 Information Management6.3.2 Control and Tracing of Production Units6.3.3 Managing the Production Bin6.3.4 Material Flow Control6.3.5 Order Processing and Operating Data Recording6.3.6 Process and Quality Assurance6.4 Performance Data6.4.1 Involved Departments6.4.2 Key Figures and Performance Record6.4.3 Ongoing Analysis and Evaluations6.4.4 More Long-Term Analyses and Evaluations6.5 Maintenance Management6.5.1 Tasks6.5.2 Preventive Maintenance and Repair6.5.3 Alarm Management6.6 Summary
7 Technical Aspects
7.1 Software Architecture7.1.1 Fundamental Variants7.1.2 Overview of Central Components7.1.3 Platform Independence7.1.4 Scalability7.1.5 Flexible Adjustment versus Suitability for Updates7.1.6 MES and Service-Oriented Architecture (SOA)7.2 Database7.2.1 Introduction7.2.2 Resource Monitoring7.2.3 Scaling the Database System7.2.4 Data Management and Archiving7.2.5 Running Maintenance7.3 Interfaces with Other IT Systems7.3.1 Overview7.3.2 Interface with Production7.3.3 Interface with an ERP System7.3.4 Interface with the IT Infrastructure7.3.5 Interface with Communication Systems7.3.6 Other Interfaces7.4 User Interfaces7.4.1 Usage and Visualization7.4.2 Reporting7.4.3 Automated Information Distribution7.5 Summary
8 Evaluation of the Cost-Effectiveness of MES
8.1 General Information on Cost-Effectiveness8.1.1 Calculation of Cost-Effectiveness8.1.2 Comparative Cost Method8.1.3 Value-Benefit Analysis8.1.4 Performance Measurement8.1.5 Total Cost of Ownership8.2 General Information on Evaluation8.2.1 Assessing Cost-Effectiveness in Practice8.2.2 Rationalization Measures in Production8.2.3 MES for Reducing Sources of Loss8.3 The Benefits of an MES8.3.1 Integrated Data Transparency8.3.2 Reducing Time Usage8.3.3 Reducing Administration Expenses8.3.4 Improved Customer Service8.3.5 Improved Quality8.3.6 Early Warning System, Real-Time Cost Control8.3.7 Increasing Employee Productivity8.3.8 Compliance with Directives8.4 The Costs of an MES8.5 Summary
9 Implementing an MES in Production
9.1 Implementing IT Systems in General9.1.1 Selection of Components9.1.2 Implementation Strategies9.1.3 Problems during Implementation9.2 Preparation of the Implementation Project9.2.1 Establishing the Core Team9.2.2 The Fundamental Decision: MES: Yes or No9.2.3 Establishing the Project Team9.3 Analysis of the Actual Situation9.3.1 Introduction9.3.2 Existing Infrastructure9.3.3 Existing Processes and Required Functions9.3.4 Key Figures as the Basis for Monitoring Success9.3.5 Suitable Key Figures for Success Monitoring9.3.6 Other Factors for Success9.4 Creation of a Project Plan9.5 Contract Specifications9.6 Selection of a Suitable System9.6.1 Market Situation9.6.2 Short-Listing and Limiting to Two or Three Applicants9.6.3 Detailed Analysis of the Favorites and Decision9.7 Implementation Process9.7.1 Project Management9.7.2 Training Management9.7.3 Operating Concept9.8 Summary
10 Examples for Application
10.1 Mixed Processes10.2 Sensient Technologies: Emulsions10.2.1 Information on Sensient Technologies Corporation10.2.2 Description of the Production Process10.2.3 Basic Quantity Units and Production Units10.2.4 Production Process Plan10.2.5 Challenges for the MES10.2.6 Realization and Implementation10.3 Acker: Synthetic Fiber Fabrics10.3.1 Information on the Company10.3.2 Description of the Production Process10.3.3 Basic Quantity Units and Production Units10.3.4 Production Flow Plan10.3.5 Tasks of the MES10.3.6 Challenges10.3.7 Realization and Implementation10.4 Summary
11 Visions
11.1 Merging the Systems11.2 The MES as a Medium of Product-Development Management11.2.1 Phases of Product Development11.2.2 Request Handling11.2.3 Concept Documentation and Designing Requirements11.2.4 Construction of the Product11.2.5 Computer-Aided Flow Planning11.2.6 Production Management11.3 Standardization of Function Modules11.4 Merging Consultancy Activities and IT Systems11.5 Summary
12 Summary of the Book
References
Glossary
Index

Overview

New global standards are the basis for new MES products that have appeared in the last five years in the marketplace
Features a comprehensive presentation of available MES technologies

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