Manufacturing execution system

Manufacturing execution systems ( MES ) are computerized systems used in manufacturing , to track and record the processing of raw materials to finished goods. MES provides information that helps manufacturing decision makers. [1] MES works in real time to enable the control of multiple elements of the production process (eg inputs, personnel, machines and support services).

MY May operate multiple across function areas, for example: management of product definitions across the product life cycle , resource scheduling , order execution and dispatch production analysis and downtime management for overall equipment effectiveness (OEE), Product Quality, gold materials track and Trace . MES creates the “as-built” record, capturing the data, processes and outcomes of the manufacturing process. This can be a very important in regulated industries, such as food and beverage or pharmaceutical, where documentation and proof of processes, events and actions may be required.

The idea of ​​MES could be seen as an intermediate step between, on the one hand, an enterprise resource planning (ERP) system, and a supervisory control and data acquisition (SCADA) or process control system on the other; But historically, exact boundaries have fluctuated. Industry groups such as MESA International- Manufacturing Enterprise Solutions Association .

Benefits

“Manufacturing Execution Systems [help] create flawless manufacturing processes and provide real-time feedback of requirement changes,” [2] and provide information at a single source. [3] MES implementation might include:

  1. Reduced waste, re-work and scrap, including quicker setup times
  2. More accurate capture of cost-information (eg labor, scrap, downtime, and tooling)
  3. Increased uptime
  4. Incorporate Paperless Workflow Activities
  5. Reduced inventory, through the eradication of just-in-case inventory [4]

MES

A wide variety of aseptic systems. Further development of these systems during the 1990s introduced overlap in functionality. Then the Manufacturing Enterprise Solutions Association (MESA) introduced some structure by defining 11 functions that set the scope of MES. In 2000, the ANSI / ISA-95 standard merged this model with the Purdue Reference Model (PRM). [5]

A functional hierarchy was defined in which MES were situated at Level 3 between ERP at Level 4 and process control at Levels 0, 1, 2. With the publication of the third part of the standard in 2005, Main operations: production, quality, logistics and maintenance.

Between 2005 and 2013, additional or revised parts of the ANSI / ISA-95 standard defines the architecture of an MES in more detail, covering how to internally distribute functionality and what information to exchange internally as well as externally. Citation needed ]

Functional areas

Over the years, international standards and models have refined the scope of such systems in terms of activities citation needed ] . These typically include :.

  • Management of product definitions. This may include, but is not limited to, the use of any of the following methods. Management of product definitions can be part of Product lifecycle management .
  • Management of resources. This may include, but is not limited to, the provision of information,
  • Scheduling (production processes) . These activities have determined the generation schedule has collection of work orders to meet the output requirements, Typically received from Enterprise Resource Planning Gold Specialized Advanced Planning and Scheduling systems, making optimum use of local resources.
  • Dispatching production orders. Depending on the type of production processes this may include further distribution of batches, runs and work orders, issuing these to work centers and adjustment to unanticipated conditions.
  • Execution of production orders. Although actual execution is done by Process Control Systems, an MES may perform checks on resources and inform other systems about the progress of production processes.
  • Collection of production data. This includes collection, storage, and exchange of process data, equipment status, material batch information and production logs in either a data historian or relational database.
  • Production performance analysis. Create Useful information out of the raw data file Managed about the current status of production like Work In Progress (WIP) overviews, and the output performance of the past period like the Overall Equipment Effectiveness or Any Other performance indicator .
  • Production Track & Trace . (S): (i ) a pharmaceutical product or a pharmaceutical product .
  • The Digitizing of the complete data from the SCADA into the common databank.
  • The Audit Interface which helps in the evaluation of the utility performance like the direct / indirect efficiency of the boiler in the runtime, cooling tower effectiveness in the runtime which is possible only if we are able integrate the complete data from SCADA System.

Relationship with other systems

MES integrates with ISA-95 (previous Purdue Reference Model, “95” ) with multiple relationships.

Relationship with other Level 3 systems

The ISA-95 Level 3 can be called Manufacturing Operations Management Systems (MOMS). Apart from year thesis are MY Typically Laboratory Information Management System (LIMS), Warehouse Management System (WMS) and computerized service management system (CMMS). From the MES point of view possible information flows are:

  • To LIMS: quality test requests, sample batches, statistical process data
  • From LIMS: quality test results, product certificates, testing progress
  • To WMS: material resource requests, material definitions
  • From WMS: material availability, staged material lots, product shipments
  • To CMMS: equipment running, maintenance
  • From CMMS: maintenance progress, equipment capabilities, maintenance schedule

Relationship with Level 4 systems

Examples of systems acting on ISA-95 Level 4 are Product Lifecycle Management (PLM), Enterprise Resource Planning (ERP), Customer Relationship Management (CRM), Human Resource Management (HRM), Process Development Execution System (PDES). From the MES point of view possible information flows are:

  • To PLM: production test results
  • From PLM: product definitions, bill of operations (routings), electronic work instructions, equipment settings
  • To ERP: production performance results, produced and consumed material
  • From ERP: production planning , order requirements
  • To CRM: product tracking and tracing information
  • From CRM: product complaints
  • To HRM: performance staff
  • From HRM: staff skills, staff availability
  • To PDES: production test and execution results
  • From PDES: manufacturing of definitions, Design of Experiments (DoE) definitions

In many cases, Middleware Enterprise Application Integration (EAI) systems are used to exchange transactions between MES and Level 4 systems. A common data definition, B2MML , has been defined within the ISA-95 standard to link.

Relationship with Level 0, 1, 2 systems

Systems Acting on ISA-95 Level 2 are Supervisory Control and Data Acquisition ( SCADA ), Programmable Logic Controllers (PLC), Distributed Control Systems (DCS) and Batch Automation Systems. Information flows between MES and these process control systems are roughly similar:

  • To PLCs: work instructions, recipes, set points
  • From PLCs: process values, alarms, adjusted set points, production results

Most MES systems include connectivity as part of their product offering. Direct communication of plant floor equipment Established data is by connecting to the Programmable Logic Controllers (PLC). Often, plant floor data is first file Managed Diagnosed and for real-time control in a Distributed Control System (DCS) or Supervisory Control and Data Acquisition ( SCADA ) system. In this case, the MES systems connect to these two levels for exchanging plant floor data.

The industry standard for plant floor connectivity is OLE for Process Control (OPC). But nowadays, it moves to OPC-UA , means the OLE is not only able to run in Microsoft Windows environment but also able to run in Linux or other embedded systems which transform the SCADA system to a lower cost, open system, and robust security.

See also

  • Enterprise control
  • Enterprise integration
  • Laboratory Information System
  • Manufacturing Operations Management
  • Process Development Execution System
  • Product Lifecycle Management
  • Purdue Enterprise Reference Architecture

References

  1. Jump up^ McClellan, Michael (1997). Applying Manufacturing Execution Systems . Boca Raton, Fl: St. Lucia / APICS. ISBN  1574441353 .
  2. Jump up^ Meyer, Heiko; Fuchs, Franz; Thiel, Klaus (2009). Manufacturing Execution Systems: Optimal Design, Planning, and Deployment . New York: McGraw Hill. ISBN  9780071623834 .
  3. Jump up^ Vinhais, Joseph A. (September 1998). “Manufacturing Execution Systems: The One-Stop Information Source” . Quality Digest . QCI International . Retrieved March 7, 2013 .
  4. Jump up^ Blanchard, Dave (March 12, 2009). “Five Benefits of an MES” . Industry Week . Retrieved March 7, 2013 .
  5. Jump up^ Johann Eder, Schahram Dustdar (2006)Business Process Management Workshops. p. 239

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