Manufacturing Execution Systems

Transcription

1 Manufacturing Execution Systems Optimal Design, Planning, and Deployment Heiko Meyer Editor Franz Fuchs Klaus Thiel Contributing Author Contributing Author Mc Graw Hill New York Chicago San Francisco Lisbon London Madrid Mexico City Milan New Delhi San Juan Seoul Singapore Sydney Toronto

2 Foreword Acronyms xv xvii 1 Introduction Motivation Aim of This Book Structure of This Book 3 2 Factory of the Future Historical Development of Manufacturing Execution Systems Development of Business Data Processing The Integration Concept: From CIM to the Digital Factory Definitions of Terms Classification of Terms Company Management Level Production Management Level Control/Automation Level Shortfalls of Existing Architectures and Solutions Patchwork No Common Database Excessive Response Times High Operating and Management Outlay Demands of Future Production Management Systems Target Management Integration of Applications and Data Real-Time Data Management Information Management Compliance Management Lean Sigma and MES Summary 30 3 Concepts and Technologies Commonalities between Existing Approaches and MES 31 vii

3 viii Contents 3.2 Norms and Guidelines ISA IEC VDI FDA NAMUR Recommendations MESA VDA VDMA ZVEI Adjacent Areas Historical Development of ERP/PPS Systems ERP/PPS Systems Process Management Systems SCADASystems Simulation Systems Product Lifecycle Management Historical Development Product Model Process Model Implementation Strategies Points of Contact with MES Summary 50 4 Core Function Production Flow-Oriented Design Cross-System Cohesiveness Classification in the Overall System General and Complete Data Model Origins of Master Data Data Model for Product Definition Relevant Concepts The Operation The Work Plan The Parts List Change Management and Product History Data Model for Resource Management Description of Production Environment Production Personnel Operating Resources Materials and Preliminary Products Information and Documents 74

4 ix 4.4 System and Auxiliary Data Order Fulfillment Data Orders Production Data, Operating Data, and Machine Data Derived Performance Data and Figures Summary 81 5 Core Function Production Flow-Oriented Planning Integration within the Overall Process Order Data Management Supply Management within the MES Demand Planning Material Requirement Calculation Material Disposition in the MES or ERP System Incoming Goods Interaction between the ERP System and the MES Material Warehousing Costs The Planning Process Planning Objectives The "Updated" Work Plan: Condition for Optimized Planning Work Scheduling Strategies for Sequence Planning and Planning Algorithms Forward Planning/Reverse Planning/ Bottleneck Planning Collision-Free Planning of a Time Container Setup Optimization and Warehousing Costs The Importance of the Control Station Core Elements User Interface Personnel Planning and Release of Orders Summary 97 6 Core Function Order Processing General Information on Order Processing Classification within the Overall System 99

5 ix 4.4 System and Auxiliary Data Order Fulfillment Data Orders Production Data, Operating Data, and Machine Data Derived Performance Data and Figures Summary 81 5 Core Function Production Flow-Oriented Planning Integration within the Overall Process Order Data Management Supply Management within the MES Demand Planning Material Requirement Calculation Material Disposition in the MES or ERP System Incoming Goods Interaction between the ERP System and the MES Material Warehousing Costs The Planning Process Planning Objectives The "Updated" Work Plan: Condition for Optimized Planning Work Scheduling Strategies for Sequence Planning and Planning Algorithms Forward Planning/Reverse Planning/ Bottleneck Planning Collision-Free Planning of a Time Container Setup Optimization and Warehousing Costs The Importance of the Control Station Core Elements User Interface Personnel Planning and Release of Orders Summary 97 6 Core Function Order Processing General Information on Order Processing Classification within the Overall System 99

6 tents Functions of Order Fulfillment The MES Terminal Order Preparation and Setup Changing Tools Machine Settings Material Provision Test Run Order Control Information Management Control and Tracing of Production Units Managing the Production Bin Material Flow Control Order Processing and Operating Data Recording Process and Quality Assurance Performance Data Involved Departments Key Figures and Performance Record Ongoing Analysis and Evaluations More Long-Term Analyses and Evaluations Maintenance Management Tasks Preventive Maintenance and Repair Alarm Management Summary 119 Technical Aspects Software Architecture Fundamental Variants Overview of Central Components Platform Independence Scalability Flexible Adjustment versus Suitability for Updates MES and Service-Oriented Architecture (SOA) Database Introduction Resource Monitoring Scaling the Database System Data Management and Archiving Running Maintenance 134

7 7.3 Interfaces with Other IT Systems Overview Interface with Production Interface with an ERP System Interface with the IT Infrastructure Interface with Communication Systems Other Interfaces User Interfaces Usage and Visualization Reporting Automated Information Distribution Summary 151 Evaluation of the Cost-Effectiveness of MES General Information on Cost-Effectiveness Calculation of Cost-Effectiveness Comparative Cost Method Value-Benefit Analysis Performance Measurement Total Cost of Ownership General Information on Evaluation Assessing Cost-Effectiveness in Practice Rationalization Measures in Production MES for Reducing Sources of Loss The Benefits of an MES Integrated Data Transparency Reducing Time Usage Reducing Administration Expenses Improved Customer Service Improved Quality Early Warning System, Real-Time Cost Control Increasing Employee Productivity Compliance with Directives The Costs of an MES Summary 169 Implementing an MES in Production Implementing IT Systems in General Selection of Components Implementation Strategies Problems during Implementation

8 ents 9.2 Preparation of the Implementation Project Establishing the Core Team The Fundamental Decision: MES: Yes or No Establishing the Project Team Analysis of the Actual Situation Introduction Existing Infrastructure Existing Processes and Required Functions Key Figures as the Basis for Monitoring Success Suitable Key Figures for Success Monitoring Other Factors for Success Creation of a Project Plan Contract Specifications Selection of a Suitable System Market Situation Short-Listing and Limiting to Two or Three Applicants Detailed Analysis of the Favorites and Decision Implementation Process Project Management Training Management Operating Concept Summary [ 195 Examples for Application Mixed Processes Sensient Technologies: Emulsions Information on Sensient Technologies Corporation Description of the Production Process Basic Quantity Units and Production Units Production Process Plan Challenges for the MES Realization and Implementation Acker: Synthetic Fiber Fabrics Information on the Company Description of the Production Process 204

9 Basic Quantity Units and Production Units Production Flow Plan Tasks of the MES Challenges Realization and Implementation Summary Visions Merging the Systems The MES as a Medium of Product-Development Management Phases of Product Development Request Handling Concept Documentation and Designing Requirements Construction of the Product Computer-Aided Flow Planning Production Management Standardization of Function Modules Merging Consultancy Activities and IT Systems Summary Summary of the Book 223 References 227 Glossary 229 Index 245