Plant Floor Visibility and MES Product Selection

Transcription

1 Plant Floor Visibility and MES Product Selection Jan Snoeij Principal Consultant North American Plant-to-Enterprise Conference September 21-23, Orlando, FL

2 MESA Strategic Initiatives The following Strategic Initiatives of MESA International are associated with this presentation: Lean Manufacturing Quality & Regulatory Compliance Product Lifecycle Management (PLM) Real-Time Enterprise Asset Performance Management (APM)

3 Agenda Introduction Plant Floor Visibility Trends and Observations Improve MES Products Product Selection - best practices Conclusions

4 Supply Chain Raw material producer Supplier Transport Factory Objective: Maximalisation customer satisfaction and and profit profit for for all all partners Factory Distributor INFORMATION FLOW MATERIAL FLOW Retail Distributor Retail Consumer

5 Rapid changes, complex environment Lowering consumer brand loyalty Increased price pressure Consolidated retail power Private label producers Regulatory requirements General Food Law Sarbanes-Oxley Shorter product life cycles Product innovation required Globalization Branding Make or buy? Where to produce?

6 Supply Chain Challenges Reduce product stock-outs Remove supply chain inefficiencies Lower inventory to reduce holding costs Reduce transportation and order management costs Raw Material Supplier Supplier Plant MATERIAL FLOW INFORMATION FLOW Transport Plant Distributor Retail Distributor Retail Reduce order fulfillment lifecycle Management of inventory replenishment process Retail & regulatory mandates Track-and-trace applications force supply chain optimization Consumer

7 Plant Performance is Key Increased "agility" (product availability) Delivery to schedule Produce to schedule Source: AMR Research

8 Plant is no longer "black box" ERP Need for full horizontal integration! Logistics and manufacturing information Financial and product(ion) information Transparency and visibility Streamlined business processes and workflows Implies highly integrated information systems, with rapid flows of accurate data MES Need for full vertical integration! Production processes must be aligned with the external supply chain in order to enable higher speed, better quality and more agility

9 Agenda Introduction Plant Floor Visibility Trends and Observations Improve MES Products Product Selection - best practices Conclusions

10 Improve Focus, make choices Consistent strategy and execution business processes organisation & people tools Strategic assets: production and supply chain(s) logistics and procurement programmes inventory cycles maintenance personnel and organisation Business processes Enterprise objectives Tools incl. IT Organization People

11 SMART Objectives 'This is the last strategy of our management!' Specific What exactly are we going to do? Measurable How much are we going to do? Acceptable Is there support for what we want to do? Realistic Is it feasible what we want? Timing When will we be ready? It is not a perfect strategy, but we apply it until we know something better!'

12 Best in Class Strategic Actions Improve processes that manage the material and information flows 64% Lean initiatieves 61% Drive standards and consistency across global manufacturing networks 43% Optimize performance at individual plants and factories 43% Improve Sales & Operations planning process 32% 0% 10% 20% 30% 40% 50% 60% 70% Source: Aberdeen Group

13 Top approaches within the plant (best in class) Standardizing plant and factory applications and control systems 46% Building flexibility into manufacturing and supply chain processes 43% Integrating systems into common factory floor information platform 36% Deploying real-time information to decision-makers 36% Consolidating the management and reporting of manufacturing information 29% Source: Aberdeen Group 0% 10% 20% 30% 40% 50%

14 Internal IT Challenges Gap between ERP and factory floor 52% Incompatible and inconsistent systems Lack of timely information to make informed decisions Lack of strategy to unify information across manufacturing 41% 37% 33% Lack of funds and/or lack of perceived value 27% 0% 10% 20% 30% 40% 50% 60% Source: MESA International

15 Integration and standardisation Prerequisites (ROI) Efficient and effective Compliant to law and regulations Flexible, agile Full integration of plant and enterprise Processes Organization Applications Data Technical infrastructure Production Maintenance Quality Inventory

16 Latency between business metrics and operations that caused them 100% 90% 80% 70% 60% 50% 40% 30% Annually Quarterly Monthly Weekly < 24 hours Source: MESA International 20% 10% 0% Business Movers Others

17 Example: Quality

18 Example: Quality (2) ACTION

19 Agenda Introduction Plant Floor Visibility Trends and Observations Improve MES Products Product Selection - best practices Conclusions

20 Participants 2008

21 Some Vendor Facts Origin North & South America 55% 47% 36% Europe 42% 46% 51% Asia & Australia 3% 9% 13% Size (employees) More than % 45% 40% Between 50 and % 18% 22% Less than 50 35% 37% 38% Established Before % 65% 55%

22 Questionnaire Vendor information General Improvements Interfaces Implementation and Deployment MESA compliance ANSI/ISA-95 compliance Technical aspects Mobile solutions

23 70% 60% 50% 40% 30% 20% 10% 0% Products per Industry Sector Electronics Automotive Food & Bev. Pharmaceutical Machinery & Tool Semiconductors Plastics & Rubber Aerospace & Defense Heavy Metals Fine Chemicals Cons.Packed Goods Paper & Pulp Life Sciences Medical Devices Bulk Chemicals Home & Pers.Care Press & Printing Petrochemical Oil Oil & Gas Utilities and Public Sector Building & Infra Mining

24 Proficy Plant Apps. Wonderware MES&EMI aspenone PI PI System Shopfloor-Online Qubes Business FLEX SIMATIC IT IT FlexNet Quartis MWare Yokogawa MIPP ADICOM Suite Dabom-iVisualizer FactoryTalk Easy95 GlobalSCREEN Hydra MES itac MES Suite MESplus PM PMS PRODAC Objective XS Suite Emerson CS/AMS Producim/Pharmacim InQu MES Mestec MES R2E-MES Unisoft CELLS Camstar Mnfg. nanotrack SAP-Visiprise Mnfg. Aegis Fusion Ampla D2000 Entis PAS-X PVSS HAI*QPM MEScontrol.net nmetric Suite Pertinence Suite Plant it it Proficy Tracker Solumina SYPROS Active Accurate Eyelit MES/QMS intrafactory WIPtrac XFP 4P 4P MES Broner MES PSImetals QMOS Operator 5 0 Focused Industry Sectors per Vendor Little Focus High Focus

25 Production & Logistical Typologies 100% 90% 80% 70% 75% 66% 79% 79% % 50% 50% 48% 40% 38% 30% 20% 10% 0% Continuous Process Batch // Semi Process Discrete Make to to Stock Make to to Order Engineer to to Order Assemble to to Order

26 Helpdesk and Support 100% 80% 60% Helpdesk + Support Helpdesk only Support only None 40% 20% 0% N. America S. America Europe M. East & Africa Asia Pacific

27 Support MESA-11 functions % 60-80% 40-60% 20-40% 0-20% Resource Allocation & Status Operations // Detail Scheduling Dispatching Production Units Document Control Data Collection // Acquisition Labor Management Quality Management Process Management Maintenance Management Product Tracking & Genealogy Performance Analysis

28 ANSI/ISA-95 Functional Model Production Production Scheduling Scheduling (2.0) (2.0) Material Material and and Energy Energy Control Control (4.0) (4.0) INVENTORY INVENTORY OPERATIONS OPERATIONS MANAGEMENT MANAGEMENT Procurement Procurement (5.0) (5.0) Source: ANSI/ISA-95 Order Order Processing Processing (1.0) (1.0) PRODUCTION PRODUCTION OPERATIONS OPERATIONS MANAGEMENT MANAGEMENT Production Production Control Control (3.0) (3.0) MAINTENANCE MAINTENANCE OPERATIONS OPERATIONS MANAGEMENT MANAGEMENT Maintenance Maintenance Management Management (10.0) (10.0) Product Product Cost Cost Product Product Accounting Accounting Shipping Shipping Admin Admin (8.0) (8.0) (9.0) (9.0) INVENTORY INVENTORY OPERATIONS OPERATIONS MANAGEMENT Product MANAGEMENT Product Inventory Inventory Control(7.0) Control(7.0) QUALITY QUALITY OPERATIONS OPERATIONS MANAGEMENT MANAGEMENT Quality Quality Assurance Assurance (6.0) (6.0) Marketing Marketing & Sales Sales Research Research Development Development & Engineering Engineering

29 100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0% Support ISA-95 Activities Standard + Configurable Production Maintenance Quality Inventory Definition Mngt Resource Mngt Detailed Scheduling Dispatching Execution Data Collection Tracking Analysis

30 Support and No Support 100% 80% 60% 40% 82% Standard + Configurable 64% 59% 52% Best supported Production activities. Support for the other activities increased more! 20% 0% Production Maintenance Quality Inventory 100% 80% No support % 2008 Consider Best-of-Breed for Maintenance, Quality and Inventory? 40% 20% 0% 33% 33% 24% 10% Production Maintenance Quality Inventory

31 100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0% Mobile Solutions per MESA Exp % 100% 80% Resource Allocation & Status Operations // Detail Scheduling Dispatching Production Units Document Control Data Collection // Acquisition Labor Management Quality Management Process Management Maintenance Management Product Tracking & Genealogy Performance Analysis 60% 40% 20% 0% 0% 46% 53% 65% 73% 62% 68% Expected % 60% 40% 20% 0% 46% 53% 65% 73% 76% 78% * Exp.2009*

32 Internal Quality System 100% 90% 80% 70% % 50% 40% 30% 20% 10% 0% ISO or CMM Own Quality System ISO, CMM or Own Certified or Assessed Valid Certificate

33 Regulatory 100% 90% % 70% 60% 50% 63% 57% 70% 50% % 30% 20% 10% 0% deployed FDA developed GAMP 21 CFR Part 11 Compliant Validation Dossier

34 100% 80% 60% 40% 20% 0% 80% 62% Architecture 84% 85% 85% 22% 67% Client/Server Load Balancing Distributed Architecture DNA Thin Client Web based architecture* SOA

35 Agenda Introduction Plant Floor Visibility Trends and Observations Improve MES Products Product Selection - best practices Conclusions

36 Staged Approach Training & Documentation Technology & Architecture Validation Processes & Systems Project Management Change Management Awareness Feasibility Specification & Selection Realization Maintenance & Support Impact Time

37 Specification and selection User Requirement Specification Technical infrastructure Vendor information (RFI) Product and tool selection Awareness Feasibility Specification & Selection

38 Selection process Long List Objectives: acceptance and active participation of all involved Convinced of: selection of "sufficiently good" MES product transparency and validity of the selection process itself Phase 1 Short List Phase 2 Final Selection Phases 1. Determine shortlist 2. Find the champion!

39 Determine shortlist Organization Focus & Scoping Knock Out & Other Criteria Get Info & Evaluate Short Short List List Involvement Management "Process owners", key users ICT department Technical department, engineering Organization Small steering group (Bigger) selection group

40 Determine shortlist (2) Organization Focus & Scoping Knock Out & Other Criteria Get Info & Evaluate Short Short List List Focus and scope Company operating policy Consistent and focused requirements

41 Determine shortlist (3) Organization Focus & Scoping Knock Out & Other Criteria Get Info & Evaluate Short Short List List Knock-out criteria (according to end users) Proven focus and experience of the vendor production typology industrial sector Availability of support Suitability of MES product Support by product of relevant main functions specific processes/activities Preconfigured solutions Regulatory compliance Quality system vendor

42 Determine shortlist (3) Organization Focus & Scoping Knock Out & Other Criteria Get Info & Evaluate Short Short List List Information and evaluation Conferences, seminars, fairs Literature Associations, market organizations, e.g. MESA Colleagues Internet Report "MES Product Survey"

43 Find the champion! Prepare Requirements Document Vendor Meetings Final Evaluation: Selection MES MES Product Product Requirements document Objectives for MES implementation Business processes within scope Required functionality Interfaces with other systems Few relevant (open) questions Specific test case (small) How does the vendor commit to your success!

44 "Open" Questions How does the vendor propose to support your business processes with his product in order to achieve the objectives? What methodology does the vendor use for executing the project successfully? What software modules does the vendor propose to use? What infrastructure and hardware will be needed? How will the interfaces with other systems be realized? What is a realistic plan and are there specific issues to take into account, e.g. availability of manufacturer s employees? What are the cost estimates for the implementation with (at least) a breakdown of hardware, software licenses and services? What is the vendor s vision and policy towards future developments, both functionally and technically?

45 Find the champion! Prepare Requirements Document Vendor Meetings Final Evaluation: Selection MES MES Product Product Meeting with Vendor Does the vendor understand your needs Is the vendor (or integrator) capable to implement succesfully? Viability of the partnership vision, cooperation, financial Roles and responsibilities Who is involved directly - organizations and individuals Reference visits

46 Find the champion! Prepare Requirements Document Vendor Meetings Final Evaluation: Selection MES MES Product Product Final choice (ranking) Functional: does the MES product fit to demands? Technical: sufficiently reliable does it fit to company's strategy and policies Financial Cultural

47 Agenda Introduction Plant Floor Visibility Trends and Observations Improve MES Products Product Selection - best practices Conclusions

48 The difference... Black-box versus "glass" factory High feedback speed Clear link between corporate strategy and manufacturing activities Knowing the metrics Focus at important aspects Use of appropriate tools (MES, dashboards,...) Plant floor visibility Delivers by far more improvement and profit / ROI Separates the winners from the rest!

49 Closing remarks "No idea!" - deadly answer? Companies knowing their shortcomings best, improve most! Metrics matter! Technology is enabler It is all about people!

50 Want to know more... Ask now or later: in our booth