Manufacturing Systems more than MES? ISPE-CaSA Educational Forum on Automation December 6, 2012

Transcription

1 Manufacturing Systems more than MES? ISPE-CaSA Educational Forum on Automation December 6, 2012

2 Flashback! - The CIM Concept 1993 SME Enterprise Wheel

3 Classification of Manufacturing Systems

4 Alternative Manufacturing Systems Model R&D, Discovery Sales & Demand Develop / Approval Master Production Operations Material Requirement Product Procurement / Receiving Process? information Production Shop Floor Management (Manufacturing Systems) Fill-Finish / Packaging Scheduling & Dispatching Logistic Shipping 4 Material & Resource

5 The Acronym Cocktail (or Mitosis) CTMS R&D, Discovery Develop / Approval PLM BI Sales & Demand Master Production ERP PDM C-CAD Operations Material Requirement Product 5 Procurement / Receiving TMS Process information LIMS Batch Mgmt QMS Shop Floor Management (Manufacturing Systems) MI Production MES SCADA / DCS EAM Scheduling & Dispatching Fill-Finish / Packaging Historian Material & Resource APS Logistic Shipping

6 ISA-95: Standard for the integration of enterprise and control systems Level 4 Business & Logistics Plant Production Scheduling, Operational Management, etc Level 3 Manufacturing Operations & Control Dispatching Production, Detailed Production Scheduling, Reliability Assurance,... Levels 2,1,0 Batch Control Continuous Control Discrete Control

7 Why is it so complicated? Software Engineering IT & IS Manufacturing Engineering Process & Engineering Industrial Engineering Operations, Quality & Logistics Controls Engineering Automation 7

8 System and Vendor Landscape Started in Industry Semi-conductor, Electronics, Discrete MES System / Vendor Rockwell Pharma Suite SAP-ME Apriso Siemens Simatic-IT Pharmaceuticals, Batch, Process Rockwell PMX (Pro-Pack) Werum Siemens XFP (Elan) Honeywell POMS Net Other Emerson Syncade 8

9 Manufacturing Systems Solution Timeline Overview Conceptualize Plan Build Operate Manufacturing Systems Governance Governance framework Programme management Application governance Technology governance Competence governance Manufacturing Systems System Strategy Project management Service & Support Solutions Conceptual Design Qualification Strategy Front End Eng./ Basic engineering Qualification MES Deploy Interoperability Deploy Qualification Go Live Life cycle planning Change Management & Upgrade Manufacturing Systems Backbone Infrastructure Strategy Project Execution Service & Support 9

10 General Benefits from MES I Review / Release by Exception The burden of batch record review is minimized nearly to nothing. Review only events that deviate from the prescribed process Compliance Elimination of paper Availability of quality records. reduction in batch record creation and review time Process Execution Reduction in incident and rework handling. Improved Work In Process (WIP) management Real time inventory Quality Effective and error-proof data entry Minimizes risk to product quality In / At-line QC Visibility into quality sources 10

11 General Benefits from MES II Data Integrity Integration with automation Order and batch information in context Intelligence/ Reporting Data fundament Employee Satisfaction Reduce operator training Eliminating redundant data entry and paper handling Empowerment through better visibility Process Standardization Drive operational excellence Propagating operational improvement and efficiency gains 11

12 One last word. "Sometimes the questions are complicated and the answers are simple." - Dr. Seuss 12

13 Vendors History 2 MESs PMX & Production Center (Datasweep) PMX is discontinued Pharma Suite built on Production Center Broad industry implementation, only recently into pharma Emerson - 1 MES product Syncade (DMI) DMI was an Acquisition Started as a Document Management product Honeywell POMS acquired by Honeywell in 1999 POMSCorp Updated to POMSnet. Mostly process customers 13

14 Vendors History Cont. Independent MES vendor (only MES) Probably 70%+ of pharma companies Very robust, best fit is for OSD Good German Engineering, but not software architecture. Simatic IT is rebranded 2 MESs ORSI Soft back in 90 s, Elan very recent Elan is very similar to Werm Unknown what they are doing with it. GE-IP a few MESs Proficy, Workflow (new), and Tracker SOA connects all products. Proficy is marketed as MI but has some MES Invensys, Wonderware was acquired. Practically no regulated experience CIMnet was aquired and integrated into Wonderware No W&D OOTB 14

15 MES Players - 1 Company Product Pharma Bio MD&D CPG Werum PAS-X X X (X) Emmerson Syncade X X Honeywell POMS Net X X Rockwell Pharma Suite / ProductionCenter Rockwell PMX (discontinued) X (X) X X X (X) Camstar Camstar Manufacturing (X) (X) X SAP SAP ME (Visiprise) X Apriso Flexnet (X) (X) Aspen Tech. Aspen ONE (X) Siemens Simatic IT (X) (X) X Siemens Elan? X Invensys Wonderware MES X

16 MES Players - 2 Company Product Pharma Bio MD&D CPG HighJump HighJump MES X GE-IP Workflow / SOA X GE-IP Proficy Plant Apps (X) Eyelit Eyelit Manufacturing Lighthouse Shopfloor online (X) X EazyWork EZ-MES (X) (X) Dessault Intercim/pertinence Solumnia ibaset

17 MI - Manufacturing Intelligence Players Company Product Pharma Bio MD&D CPG Rockwell Metrics/Trends (X) X Rockwell VantagePoint X (X) Aegis Discoverant X X SAP SAP MII X X X Wonderware Wonderware Intelligence X (X) informetrics InfoBatch Parsec TrakSys (X) (X) ABB cpmplus (X) Siemens Production Intelligence (X) GE-IP Proficy Plant Apps X mydials mydials? Honeywell Matrikon Production Manager X (X)