Nov 232011

 

 

MES


Manufacturing Execution System (MES) refers to a computer system which has the main function of managing and controlling the production of a company. The management involves the dispatch of orders, quantitative and time monitoring, storage handling , as well as direct connection to machinery. This is done to deduce information useful for the production and so to produce information for the control of it. After the advanced state of business control developed in the late 90s that spread leveraging a highly automated industry, today we feel the need to ask ourselves much more targeted questions. What are the factors of our manufacturing process that affect the business? To synchronize and coordinate these two components, MES was born (Manifactory Execution System). Thanks to the adoption of standard (ISA-95), MES allows to apply to the main areas of any type of production a simple generic model capable of synchronizing multiple levels of the business functionality. The goal of MES is to reduce the risk, cost and errors associated to the implementation of an enterprise system and management of production operations, simplifying and facilitating the integration of the various functions.

The activities of production management are those activities within a production function to co-ordinate staff, equipment, and material, processing of raw materials and / or the conversion of parts into products. The management of production functions include activities that may be carried out by physical equipment, from human labor and from computer systems. By performing these activities of production management, we reach the mission of the business. The management of production activities include the activities of managing information about the schedule, the use, production capacity, history and the condition of all the resources (personnel, equipment and material) inside the production unit. ESEA aims through ESEA Automation srl in collaboration with Siemens spa, to provide the solutions best suited to individual contexts and realities of the production, for the construction of a proper flow of business information.

WHY MES

The market demands: flexibility, modernization, competitiveness and quality.
All companies are now equipped with automated machines and a multitude of management programs, often robots, and many companies are also equipped with supervisory systems or computer vision. The only weapon remaining available to the contractors and technical delegates to reduce costs without reducing quality, is the MES. Organizing your work with MES means doing the same work with fewer people and thus having an impact on the recovery of productivity and quality. Years ago the staff employed in the administrative offices of a company represented fairly significant percentage of the total employees. The need to simplify the accounting, has prompted companies to equip themselves with management software that simplify all fiscal operations, personnel management, etc.. organizing the work of employees and reducing their number greatly. On the other hand, try to imagine what it would mean to better organize the work in production environments, where the percentage of human resource and the resulting management issues are much higher. The reduction and better distribution of staff would result in increased productivity and quality improvement, because organization is the foundation of every business.
MES is the link that binds the management software company to what the machines produce. A ring that manages the stock of materials, which can give real-time data to make critical decisions at the right time. But MES is not just a software; MES is a philosophy of work translated into pure practicality, a sense of democracy in the labor guide, because it drives every single component of an activity. Working with MES means working with strategic openings, working organized and constantly evolving. In order to make strategic decisions for the entire company, all production information must be recorded and shared by all sections and departments, from the warehouse and supply of raw materials, from the production departments and organizational decision-makers to the quality, from the heads of department to the individual line operators.

With proper analysis and representation of the information you can get strategic goals for the company:

  • lighten the stock with a reduction of costs and, therefore improving and reducing the delivery time (lead time);
  • point to a methodology based on the planning of procurement and production to order, real-time (JIT: ​​Just in Time);
  • govern the flow of work;
  • measure the efficiency of the machines;
  • manage the traceability and genealogy;
  • monitor performance indicators KPI (Key Performance Indicator) in order to measure the success of the business strategies both in terms of production

MES is the future of the market and competitiveness.

Brief description of the functional areas of  MES

 

  • Business management systems ERP (Enterprise Resource Planning) for optimal planning activities, building a shared data warehouse DW (Data Warehouse) in order to facilitate the process of decision-making;
  • Advanced management of business planning APS (Advanced Planning and Scheduling) manages the strategic planning processes in order to integrate supply – demand – production – logistics;
  • Process Management BPM (Business Process Management) – managing the flow of work in the plant according to the activities of current and planned production;
  • Factory resource planning MRP (Manufacturing Resource Planning) – infinite capacity scheduling CRP (Capacity Requirements Planning), which are to optimize the consumption of materials, the use of men and the use of machines, according to the orders and availability;
  • Scheduling of operations and detailed MRP (Manufacturing Resource Planning) activity sequencing and timing to optimize the performance of the systems, taking into account the finite capacity of the resources available;
  • Allocation of resources and CRP (Resource Allocation and Status) production work instructions intended for personnel, machines, tools and materials. Tracking the activity in progress or recently completed;
  • Labor management LM (Labor Management) – tracking and management of operational staff during the individual rounds on the basis of qualifications, duties and business needs;
  • Collection / data acquisition DC (Data Collection / Acquisition) – monitoring, collection and organization of data on processes, materials and operations performed by personnel, equipment or controls;
  • Tracking and genealogy of PTA products (Product Tracking and Genealogy) – monitoring the progress of units, lots or batches to create a complete history of the products, in conformity with the regulations 21 CFR part 11;
  • Quality Management QC (Quality Control) – recording, tracking and analysis of the characteristics of products and processes in accordance with the objectives set by the statistical control of production processes SPC (Statistical Process Control);
  • Performance Analysis of KPI (Key Performance Indicator) and calculating the overall efficiency of the equipment OEE (Overall Equipment Effectiveness) with the analysis of downtime DTA (Down Time Analysis), comparing the results measured in the system with the objectives and the parameters set by the company, by customers or by standardizatio;
  • Optimization of production cycles WIP (Work in Progress) – minimization of production time optimizing the production cycles;
  • Maintenance Management MM (Maintenance Management) – planning and implementation of appropriate activities to maintain equipment and capital goods under optimum conditions;
  • Management of the value chain SCM (Supply Chain Management) to minimize the costs of procurement, production and delivery areas where logistics plays a key role in the integration of the chain supplier-manufacturer-customer;
  • Document Management ADR (Automatic Document Repository) – management and distribution of information on products, processes, projects or orders, in addition to collecting information on the certification of employment opportunities and conditions;
  • Management systems and customer loyalty CRM (Customer Relationship, Management).

 

ESEA AND SIEMENS


To carry out its mission, ESEA has chosen a partner who can provide assurances of reliability, continuity, support for the future and invest continuously updating and upgrading of its modules to technology hardware and software. With the speed with which PC and SERVER become outdated and with the continuous updating of operating systems that make software applications soon unusable, in fact, it becomes costly for companies to keep pace with the market of IT (Information Techonology). Thus was born the partnership with Siemens, a story and a name in the world of automation.

Siemens is not a simple software house made from a few technical indispensable and irreplaceable for technical assistance and management of the necessary updates. Siemens is one of the major nework international practices. Its size and operational capabilities have no boundaries, in fact, it has offices, manufacturing units, research and support centers in more than 190 countries around the world with the collaboration of more than 461,000 professionals. In addition, Siemens is certified Microsoft worldwide. For these reasons, Siemens, due to its location and its complete, is one of the few companies able to offer itself as a global partner.
The leadership position that Siemens has built within MES is undoubtedly derived from the many peculiarities of its product.

The product is:
Modular and scalable

To expand the existing system, at any time you may want to add and integrate new modules to existing MES.

Flexible and open

It is a development system fully open. Siemens organizes and provides training and support to the development and maintenance of their systems constantly.
ESEA Automation with SIS (Siemens IT Solutions and Services) and in collaboration with Siemens Automation and Drives Group, is pleased to announce the new SIMATIC IT Enterprise – Manufacturing Interoperability Layer.

Specifically dedicated to the IT, Logistics and Production departments, this solution addresses aspects relating to interoperability between the planning system ERP (such as SAP) and the system of checks and progress of production (MES), directly connected with the sensors and actuators on the production lines.
The solution was developed in close cooperation with Siemens Automation & Drives, for years a leader in MES and supply of devices for industrial automation.

SIMATIC IT


SIMATIC IT is not a preconceived solution. SIMATIC IT conforms to the existing reality through its “Production Modeler” which lets you design your business processes with maximum flexibility and subsequently manage it dynamically with a series of modules / standardized functions. SIMATIC IT follows production from the issue of order to the delivery of the finished product optimizing effectiveness, efficiency and cost reduction.
For a systematic management of production SIMATIC IT is the ideal solution as proven in many companies large and small, in particular for
all the organizations that require a precise traceability of products, processes, in compliance with the rules of international law.
SIMATIC IT MES software increases production efficiency while reducing costs and speeding up the project proposes an IT system specifically designed for the manufacturing environment and areas related to it.

SIMATIC IT, the modular MES solution from Siemens offers a wide range of components to optimize the planning, execution and documentation of the production process, thus maximizing efficiency.
But SIMATIC IT is much more: as part of the world TIA (Totally Integrated Automation) is based on a rigid standardization of interfaces, a programming structure following to the standard ISA-S95, and high compatibility in the long run with all Siemens components or any third parties. This ensures a consistent integration of all processes, from the sale, from the laboratory to the safety system, with a constant flow of information between the various levels of the company.

Next to SIMATIC IT Production Suite, SIMATIC IT Intelligence Suite and SIMATIC IT R & D Suite are dedicated respectively to the management and archiving of all business data and the optimization of R & D according to the criteria of efficiency and reduction of the time-to-market.

The heart of the SIMATIC IT Production Suite consists of pre-defined and easily configurable modules: the Framework, a high-level configuration environment, which provides the elements for the configuration of the desired plant model, characterized by intuitive engineering high quality tools and a range of Components, which provide full coverage of the functionality of the process, acting as a bridge between the environment and ERP systems, automation and control.

The model used by SIMATIC IT describes all physical and logical elements in the system. The first are those actually used in the production cycle, such as reactors, mixers, packaging lines or more complex units such as assembly lines or a continuous casting line. The logic elements are all those software components that help implement the manufacturing cycle with the aim of managing the information necessary to trace and orchestrate the entire production.
To facilitate this activity SIMATIC IT provides a complete set of type libraries. These collections are built-in functionality that can contain both types of logical and physical elements, simplifying the configuration process. Some examples of libraries are:

  • Tank Farm Management (tanks);
  • Label Printing Management (labeling);
  • Trucks Check-in and Check-out (managing deliveries of raw materials and finished product sampling);

The different collections of libraries are grouped into Basic Libraries, Libraries and Discrete Process Libraries.

In this way the system is able to receive and validate data, compare them with the reference parameters, perform calculations, send commands to the process, interface with the various business areas of the plant (production, technology, laboratory, planning, maintenance, etc. .) by sending and receiving information suitably aggregated and processed. The user is then able to react appropriately to the stress of the process by distributing the different levels (process, MES and ERP) their decision-making tasks.

SIMATIC IT is integrated with the Siemens automation products such as WinCC and PCS7 and can capture not only direct process values, alarms and events from the field, but it can also interface with third-party systems via OPC connections. Moreover, the experience gained over the years in the field of industrial and automation in general ESEA in particular, allows ESEA Automation to interface with any type of information in this field.

THE OFFER
Design, implementation and realization of the MES may be built with a wide range of modules and may be expandable in terms of functionality, complexity and size:

Simatic IT Description
Material Manager Module for the management of materials
Production Order Manager Module for the management of production orders
Historian Module for the acquisition and aggregation of real-time data system
Personnel Manager Modulo per la gestione del personale produttivo
Report Manager Module for the management of personnel in production
Data Integration Service Module for the integration of SIMATIC IT with third party software (such as SAP)…
Product Definition Manager Module for the management of the different bases of product and processing cycles…
Message Queue Connector Module for the management of messaging
Unilab Module for the management lab
Interspec Module for the management of the variants
OEE Comparison module for the programmed/scheduled and the product

 

MATERIAL MANAGER is a set of software components that handle the materials in their entirety; the features that make up the module are:
Management of the movement of materials within the production plant;

  • Management tracking and tracing;
  • Management and summarizing material consumption;
  • Management of bills of materials, versioning;
  • Genealogy of the product;

Management of allocations in the production area. It is an important module for the management of essential materials for food companies, but also for those who want to improve manufacturing warehouse stocks optimizing the supply.

ORDER PRODUCTION MANAGER is a set of software components that track and trace production orders) and it is the heart of any system of production management MES. What to produce, when to produce and how, are the entries that summarize the concept of POM (production order manager). Through this form you can:
Import production orders from management systems ERP (Enterprise resource planning);

  • Create/configure new production orders;
  • Sort the various orders in the various work centers;
  • Monitor the progress of orders;
  • Store the order data when closing it;
  • Optimize the progress management of orders (Tracking).

It is an important module for the management of the production for manufacturing companies that want to monitor the progress of the production.

HISTORIAN is a set of software components that aggregate production and process data from various sources, the main features are:

  • Aggregation process data (data from the machines, operators);
  • Aggregation Alarms and Events;Data aggregation batch;
  • Aggregate production data (production orders, production batch);
  • Aggregation process data with production data;
  • Calculation of statistics and historical data;
  • Definition of algorithms and calculations by the user;
  • High-performance data storage (1000 tags per second);
  • Reporting evolved to the consultation of the data;
  • Structured Storage for full compatibility with 21 CFR 11;
  • Direct interface with WINCC;- Interfacing to I / O field.

It is an important module for the management of process data, especially for companies that have a high degree of automation, the module allows monitoring in an efficient and effective way, controlling every single I / O on the field.

PERSONNEL MANAGER is a set of software components that allow you to manage and configure the personnel within the production site. These are the relevant features:

 

  • Define and configure groups of people and individuals, based on their skills and what they can do within the production process;
  • You can plan and allocate individuals or groups of people to carry out specific activities;
  • Historicize the work time for each person or group associating to it a resource, an order, a lot.

It is a secondary module for the management of production and can be useful to companies that want control over the production process and also the proper use of human resources within the factory.

REPORT MANAGER is a set of software components that allow you to easily create and manage the reporting of the factory, the module allows you to:
Easily create reports ad – hoc;Quickly access the database factory to obtain information critical to the decision-making company;Significant reduction in the use of paper;Greater sharing of information.is a secondary module for the management of production, but many companies are sensitive to the fact of being able to customize reports at will.

PRODUCT DEFINITION MANAGER is a set of software components that define in detail the product, the module, the module allows:
Definition of the specific resources that perform a particular operation (eg oven temperature to be set for cooking);Definition of material resources, production resources and personnel;Definition of the sequences (the predecessor-successor) between the individual operations within the cycle.is a secondary module for the management of production, in complex manufacturing processes often involves managing the various stages of production. Are sensitive to those companies which perform a very precise and detailed control on productive activities pushing himself to a finite capacity scheduling of resources (machines, men).

DATA INTEGRATION SERVICE is a set of software components that allow you to easily integrate SIMATIC IT platform with third-party products (eg operating systems):
Communicate with third-party software primarily through XML standard;Allows you to manipulate data using the standard XSLT;Using a standard format;Please Logging and archiving of transactions between a SIMATIC IT platform and third-party products.It ‘a secondary module for the management of production, can be used in reality are medium to large size to exchange information with the company management standards, such as SAP, management or custom and personalized.

MESSAGE QUEUE CONNECTOR is a set of software components that allow you to generate an activity of messaging within the factory.
Its importance is the fact that it is a module that can be useful in the pharmaceutical companies who want to monitor every single operation that makes the operator.

Unilab is a set of software components that allow you to manage laboratory analyzes interfacing to dedicated tools (such as spectrum analyzers).
is a secondary module that can be useful in food companies that have a laboratory analysis to be integrated with the production process.

Interspec is a set of software components that allow you to manage product variants.

Overall Equipment Efficiency is a set of software components that allow you to manage and measure in detail the efficiency of productive resources, setting up a number of parameters can be monitored quickly.

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