Enterprise resource planning Product life-cycle management Manufacturing operations management Information systems in industry ELEC-E8113

Transcription

1 Enterprise resource planning Product life-cycle management Manufacturing operations management Information systems in industry ELEC-E8113

2 Contents Enterprise resource planning (ERP) Product lifecycle management (PLM) and product data management (PDM) Manufacturing operations management (MOM) Rationale of the lecture: ERP and PDM/PLM are important information systems in industry but not our focus. There is data transfer between them and MOM, and that is why we need to know them.

3 Basic concepts Enterprise resource planning (ERP) is a very essential information system in almost any industrial company. It is used for management of business and logistic operations at enterprise level. Product life-cycle management (PLM) refers to activities and information systems used for management of information about products during all stages of their life-cycle. Product data management (PDM) can be regarded as part of PLM. Manufacturing operations management (MOM) refers to the business processes needed for managing (not performing) production activities in industrial companies. Manufacturing execution system (MES) is an information system designed to support the human activities of MOM. 3

4 Enterprise Resource Planning (ERP) ERP means management, i.e. planning, performing, coordinating and monitoring the core business processes of a manufacturing enterprise, and management and communication of information about it ERP covers both logistic and business processes ERP usually refers the supporting information system. The processes are sometimes called business operations management (BOM) ERP MES PDM 4

5 Functionality of ERP ERP is often divided into modules according to different supported business process Core modules include inbound and outbound logistic, production planning, accounting and controlling The modules share a database representing information of the enterprise Modules communicate with each other and update status information of the enterprise consistently 5

6 Example: customer order delivery process The process starts with sales forecasting and processing of orders Production planning involves material requirements planning and master scheduling Orders are released to SFC (i.e. MES) and feedback monitored The process ends with shipping, delivery and billing MOM/MES 6

7 Data of ERP The database of an ERP contains various data, including: Organizational data: customers, suppliers, production sites, etc. Product data: products, material and capacity requirements of products, product inventory, product shipments, etc. Material data: materials, material inventory, material shipments, etc. Resource data: resource groups, capacity, availability, also human resources, etc. Demand forecast, production plan and performance, possibly also other types of plans e.g. maintenance Business information for accounting and controlling Performance indicators 7

8 Location and people views to ERP Global ERP (i.e. just one ERP in the enterprise) is not the only option in practice Partial centralization either with respect to location or function is not uncommon ERP has several different users groups with different access rights in various parts of an enterprise. Many of them are office workers. 8

9 ERP system architecture ERP is a database-oriented server application with multiple user groups and functionality supporting BOM Data exchange with several other information systems 3-tier system architecture is common Thin user interface containing just presentation, e.g. web browser Application server containing application logic of various modules Database server providing common data storage Other systems User interface - presentation Application server - modules Database server - shared data 9

10 Other systems than ERP ERP is not the only information system for enterprise activities, e.g. Customer relationship management (CRM), Supplier relationship management (SRM), Supply chain management (SCM), Product lifecycle management (PLM), integration platform, custom add-ons and even more other systems The combination of diverse information systems in an enterprise varies considerably depending on type of industry and individual companies 10

11 Objectives and challenges of ERP Intended benefits of ERP include Faster and more efficient operation, and decreased unproductive work More precise and more real time information about the status of the enterprise Unification of the operations of the enterprise, e.g. through so-called best practices Potential issues with ERP High cost of commissioning e.g. due delays in the project High cost of making changes afterwards Issues with usability Objectives are not necessarily met, evaluation of results is difficult Vendor lock-in 11

12 Product data management PDM and PLM are both data management activities that store and deliver product data to other activities of an enterprise Both can refer either to activities or supporting information systems PDM has narrower scope, typically product design. PLM is needed particularly for aftersales services 12

13 Product data and items Any data related to products Data in databases Electronic documents Paper documents Data from any phase of product lifecycle Product types including product development, subcontracting, commissioning, usage, maintenance, revisions, disposal Product individuals including the similar phases for each separate individual product Items are the basis for managing product data Item is an element that is repeatedly referred to, e.g. product, part, material, document, etc. Identification, a string, given systematically, may be classifying Description as human readable text Items are different in separate companies Classification to hierarchies which are typically compromises between different users Revisions, variants and tatus Suppliers and manufacturers Other data, possibly >

14 Structures, documents, versions and status Structures of items There several structural views a product, e.g. design, control, production and materials Hierarchical and recursive data structures e.g. with has part and made of relations Document items Typically a document item is stored to database with a link to the actual content From the data management viewpoint documents are non-structured data Items can have different versions that may be either revisions or variants A revision replaces the original one whereas variant does not Items have lifecycles with different statuses during it The statuses control the utilization of items in different activities, e.g. accepted to production 14

15 Product data models A few specifications or standards have been developed for modeling selected aspects of product data in different industries. Actual adoption of these specifications varies. Examples: ISO 1303, STEP - Standard for the Exchange of Product model data, a broad standard for representing structure and geometry of products particularly in machine building industry ISO 13584, PLIB - Parts Library, a standard for describing technical components ISO 15926, Integration of life-cycle data for process plants including oil and gas production facilities, a standard for describing equipment and process plants in oil industry 15

16 PDM system architecture PDM systems are data management systems that combine product data stored both in a database and documents Items are stored into a (meta- )database Documents are typically stored separately Multiple user groups with different access rights Data exchange with several different other information systems (e.g. ERP) 16

17 Objectives and challenges of PDM Intended benefits of PDM include Faster access and delivery of product data within an enterprise leading to decreased number of errors and less unproductive work Better updated information about products in the enterprise Particularly faster product design through concurrent work and efficient reuse of existing product data Better management of changes in product data Potential issues with PDM Large number of items, complexity of product structures Product data management in an enterprise network 17

18 After-sales services and PLM After-sales services are an important motivation for PLM After-sales services include services of equipment vendor for several stages of product usage: Commissioning, e.g. installation, training, start-up Usage, e.g. condition monitoring, fault diagnostic, maintenance, performance monitoring Changes, e.g. extension, modernization, relocation, disposal, recycling Although many of these activities utilize product data they also require other types of data PLM is not enough for these activities, e.g. ERP support for services is needed and CBM for maintenance 18

19 PLM in a supply-chain PLM during delivery and after salesservices of products like industrial devices takes place in a supply-chain of many companies Product data is managed within the vendors, communicated between them and to the customer Companies are developing their PLM operations both separately and as a group. The customer will manage part of the product data as resource data 19

20 Layer model of enterprise business processes (BOM and MOM) MOM (i.e. MES) is between BOM (i.e. ERP) ERP and automation in functional hierarchy Concerns about manufacturing, not so much about business Local scope (production site), not enterprise Shorter time span, data more realtime and more detailed than in ERP Interface to production process is mandatory Interfaces typically within the enterprise 20

21 Interface between BOM and MOM Part of the model of MOM activities in the ISA-95 standard The interface between MOM and BOM (i.e. ERP) vary in different companies Four different types of operations management: production, inventory, quality and maintenance 21

22 MES system architecture MES is a database oriented server application with multiple user groups and functionality supporting MOM 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 common data storage All three parts have to be configured for an application ERP, PDM, etc. User interface - presentation Automation Application server - modules - interfaces Database server - shared data 22

23 Readings Sheldon, D. H. Class A ERP Implementation: Integrating Lean and Six Sigma, J. Ross Publishing, Sääksvuori, A., Immonen, A. Product Lifecycle Management, Springer, Kletti, J. Manufacturing Execution System MES, Springer,

24 Homework Just one question about MES (background for planning and monitoring lectures) based on selected text Deadline Answers to 24