Manufacturing operations Part 2: Operations monitoring & MES Information systems in industry ELEC-E8113

Transcription

1 Manufacturing operations management (MOM) Part 2: Operations monitoring & MES Information systems in industry ELEC-E8113

2 Contents Monitoring operations as part of MOM Manufacturing execution system (MES) Rationale of the lecture: Monitoring operations is another essential part of MOM in addition to planning. MES is an information system designed to support human activities of MOM.

3 Basic concepts Manufacturing operations management (MOM) refers to the business processes needed for managing (not actually performing) production activities in industrial companies Manufacturing execution system (MES) is an information system designed to support the human activities of MOM. 3

4 Production operations management Typically the most important operations in discrete part manufacturing Starting from work orders from ERP and process plans from PLM Creation of operational commands for automation Recording response for reporting, analysis and traceability Varies in different industries 4

5 People and objective views to MOM Decisions in MOM are typically made by humans. MES support decision making providing access to data and information processing tools The basic parts of operations monitoring are tracking and performance analysis. Both are based on data collection Tracking has a shorter time frame and answers the question: did the operations take place as planned Performance analysis has a longer time frame and answers the question: were the operations planned and done well 5

6 Performance data Performance data is the counterpart of schedule data for tracking For example in case of production: Production performance consists of a set of production responses Production response describes the actual usage of resources Production response also describes the actual start and end times of production tasks 6

7 Key performance indicators (KPI) Longer term analysis typically consists of calculating industry specific selection of KPIs A few common KPIs: Delivery reliability (on-time delivery) Total manufacturing lead time Throughput time Production costs Own quality (in terms of reclamations, post-deliveries and warranty costs) Supplier quality WIP (work in progress) OEE (overall equipment effectiveness) 7

8 Example: OEE calculation Calculation of KPI (Key Performance Indicators) is a typical application of monitoring oriented MES OEE (Overall equipment effectiveness) is a well-known standardized KPI that is typical particularly in batch and process industries OEE = availability * performance * quality Availability is the percentage of scheduled time that the operation is available (uptime) Performance is the percentage of actual production speed of the designed maximum speed Quality is the percentage of acceptable production of started production 8

9 Production dashboards Dashboards is a part of MES user interface used to communicate analysis and tracking information to human users Basic types of dashboards: Strategic: overview of the situation (most important KPIs) Tactical: detailed information about a particular topic Operational: what should be reacted to right now (tracking) Appropriate visualization is important in dashboards 9

10 MES system architecture MES is a database oriented server application with multiple user groups Separate user interfaces for management and shop-floor personnel Application server is typically divided to modules and provides interfaces to automation and information systems Database server provides a common data storage All three parts have to be configured for an application Information systems User interface - presentation Automation systems Application server - modules - interfaces Database server - shared data 10

11 Manufacturing execution system (MES) MES are information systems designed to support MOM Support most of MOM activities Extensive data storage of MOM data Central point of communication about MOM MES is intended as an integrated information system for MOM for replacing older separate systems and manual work 11

12 Information system interface, e.g. SOA User interface, e.g. Web-based Modules of MES An archetype of MES would consist of the following parts: Planning module(s) Monitoring module(s) MES Planning modules Detailed scheduling Dispatching Tracking Monitoring modules Analysis Tracking Historian Information system interface(s) Automation interface(s) User interface(s) Automation interface Execution Data collection Historian Data collection In addition, there would be application development tools for configuring the system 12

13 Information system interface, e.g. SOA User interface, e.g. Web-based Planning oriented MES One basic type of a MES application is planning oriented MES, which is common in discrete part manufacturing The essential modules of this MES would support detailed scheduling, dispatching and tracking of production (and possibly some other) operations ERP interface would be mandatory but automation interface optional User interface would be particular to scheduling Planning oriented MES Planning modules Detailed scheduling Dispatching Tracking 13

14 User interface, e.g. Web-based Monitoring oriented MES Another basic type of a MES application is monitoring oriented MES, which is common in process industries This MES would have modules for tracking and analysis of particularly quality operations ERP interface would be optional but automation interface mandatory User interface would be particular to reporting and often web-based Monitoring oriented MES Monitoring modules Analysis Tracking Automation interface Data collection Historian Data collection 14

15 Interface of MES with other information systems Interface between ERP and MES, i.e. which activities are in scope of either system, varies in different companies Beside is an imaginary example of allocating MOM activities to ERP and MES Maintenance and part of inventory operations management is usually out of the scope of MES 15

16 Interface of MES with automation systems Interface between MES and automation varies in different industries depending which systems are used for automation DCS, PLC and historian may be used to implement some of the MOM activities A consequence of varying interfaces of MES with both information and automation systems is that sometimes no MES is needed at all. MES MES PLC DCS Historian 16

17 MES integration In addition to supporting MOM activities, another possible role of MES is to integrate production to ERP, PLM and even other information systems and business processes of an enterprise and a supply-chain The figure illustrates a larger set of possible connections that MES in principle could facilitate 17

18 Integration with ERP and PDM Integration between MES and information system can be defined as exchange of messages: Transactions, i.e. conversation between parties Content of messages Format of messages, e.g. XML Technology of message transfer, e.g. file transfer, WS, database connection Configuration of integration is needed due to differences in processes and systems 18

19 Integration with automation Also integration of MES with automation can be modeled as exchange of messages Commands, responses, other events Measurements, particularly quality Production instructions, e.g. recipes, NC-programs Integration with automation depends considerably on the type of production Note also the role of human labor 19

20 Example: Batch process automation Virta, J., Application Integration for Production Operations Management Using OPC Unified Architecture, MSc thesis, Aalto University, Activities of batch process management are divided between MES and PCS Both expose relevant data through OPC UA servers with ISA-88 information models SOA-type orchestrations were used for configuring required message exchange defined according to ISA-88 20

21 Intended benefits of MES MES is expected to facilitate the following positive effects in MOM: Monitoring related benefits: more timely data about relevant aspects of manufacturing, better tools for data analysis, increased data-based decisionmaking both during production and afterwards (traceability, development) Planning related benefits: Better tools for more real-time planning of manufacturing operations Integration related benefits: Better vertical integration of ERP and manufacturing The effect of MES to KPI depends on the type of industry, e.g. Shorter throughput time and more reliable deliveries Decreased WIP Better quality to customers 21

22 Beyond MOM and MES There are business processes partially similar to MOM and information systems to some extent similar to MES in associated application areas No production, but materials management Warehouses with their Warehouse management systems (WMS) are a typical example No products, but services Maintenance services for customers is a common example of this Also other types of services, e.g. logistic services (vs. WMS) Resources are not local, but accessible over the Internet Resources do not need to physically local, e.g. demand response in power systems 22

23 References Kletti, J. Manufacturing Execution System MES, Springer, Meyer, H., Fuchs, F., Thiel, K. Manufacturing Execution Systems: Optimal Design, Planning and Deployment, McGraw-Hill,

24 Homework Two questions about SOA based on selected texts Deadline Answers to 24