FraME- Framework for Manufacturing Execution. Integrating Product lifecycle with Manufacturing Execution & supply chain processes

Transcription

1 FraME- Framework for Manufacturing Execution Integrating Product lifecycle with Manufacturing Execution & supply chain processes

2 Table of Contents 1 Introduction 3 2 HCL Solution Approach Framework for 4 Manufacturing Execution (FraME) 3 Features 5 4 Case Study 6

3 1. Introduction Manufacturing companies continue to face challenges in aligning business strategy with business processes. Even when leading companies make an effort to share and integrate with their partners, most of them rely on a highly manual process and information from a tangle of Enterprise Resource Planning (ERP), Customer Relationship Management (CRM), Supply Chain Management (SCM), Product Lifecycle Management (PLM), Product Data Management (PDM), Workflow, Web and legacy applications and so on to coordinate order fulfillment across corporate divisions and external partners. Developing an end-to-end business process or even one that crosses one or more functional corporate boundaries is made more difficult by the existence of functional software systems. On one hand, current BPM offerings focus on addressing humanto-human processes, but do not completely handle transactional processes, and do not manage product data. On the other, PLM provide significant value but there are no fully integrated offerings in the market that fully cover every aspect of a product lifecycle. Other solutions are employed to enable manufacturing, sales & service aspects of these product lifecycles. The integration of all these product related processes require both connectivity & cross application support in a way that entails both process & data integration. This paper showcases FraME which leverages an approach that helps overcoming these challenges, through our process orchestration framework. FraME helps orchestrate business processes in a manufacturing environment that provides a high degree of flexibility for change with good visibility into the business process execution. Engineering Change Management is an area where there is tight integration between the systems which leads to less visibility among the business transactions. Typical Current ECM process as shown in the figure below involves the following steps 3

4 Sales request or a new product introduction triggers the Engineering Change Order (ECO) process. The triggered ECO has to go through various levels of approval stages. After the ECO has been approved PLM interacts with MES to download the product information into MES. PLM then sends the inventory BOM items to inventory systems. PLM then sends the costing details & required BOM items to costing system. Finally PLM updates the product information, lead time & supplier information. 2. HCL Solution Approach Framework for Manufacturing Execution (FraME) HCL s existing framework SynAps provides a holistic framework for improving manufacturing operations efficiency and collaboration between engineering and manufacturing systems. However our survey on SynAps indicates that 86% of our customers want to address Process Orchestration; 65% of the customers need Vertical specific out of the box templates and dashboards. Thereby HCL has invested in enhancing the framework as FraME. 4

5 FraME addressing the challenge FraME leverages BPEL and provides an automated way of orchestrating the process and captures best practices as an executable script. The benefit is in reduced effort required for any changes in any of the participating systems as well as applying the best practices to a new environment and thereby reducing the time to deploy. These scripts could be run using any system that supports variety of industry standard BPEL scripts like MS BizTalk Server, Oracle BEPL Process Manager and IBM Web Sphere Business Integration Server Foundation. FraME is a product and technology agnostic tool which helps to capture generic and domain related processes captured as BPEL scripts based on best practices. It helps in integration across applications in engineering, shop floor and enterprise FraME also helps in enablement by providing process templates for vertical focused business processes as well as vertical focused standard analytics, reports and dashboards. FraME makes use of the MII for providing the analytics, reports and dashboards thereby making sure that a widely accepted platform is used for easy integration and maintenance. FraME Process Orchestration happens through Biz talk server,.net web service Component (SOA/WOA). It integrates PLM, MES, Inventory System, Costing and Sales & Distribution System. FraME manages and monitors the process orchestration execution and tracks the log which helps in checking the status & updates. It provides a real time update about the status of process orchestration through dashboard 4. Features FraME has a Generic tool i.e. Process orchestration Dashboard that provides unified visualization of events, that supports the real-time status monitoring for any configured systems in FraME. Within a single view, we can clearly quantify the businesses performance across a wide range of processes with real-time information that is tied directly to the execution. It also captures the overall process performance of different systems The Architecture allows configuration of system names and parameters to be displayed. The required business systems can be configured for real time monitoring in FraME. 5

6 FraME also shows a real time view of PLM, MES, Sales & Distribution, Inventory & costing system ECM process execution status along with time log details. It also provides execution log information of each individual system. The Log information can be configured as per the implementation needs. Execution log information of PLM system captures ECO status, Basic information about ECO along with BOM. Execution log information of MES system captures assembly item s key information along with BOM items of ECO and workflow name as generated from the MES system is linked with the ECO. It displays the basic information as well as the BOM details. Basic information such as part type, device version along with package code & workflow code can be visualized in real time. BOM showcases the item level information. Log information helps in tracking the status Execution log information of Sales & Distribution system captures ECO information along with the relevant BOM items with leadtimes, Supplier name etc. It shows the basic information about the part type, lifecycle phase and package details Execution log information of Inventory Management system captures, In/Out relationship among the BOM items and the workflow name as extracted from MES systems for tracking. This serves a master data for Inventory to track the movement of Lots in MES and provide visibility to costing and order status. 5. Case Study Scenario: Integration PLM, MES, Inventory, Costing, Sales & Distribution for Engineering Change Management process Business challenges: Frequent changes in sales order (30 change request per months)& new product initiative (6 new product introduction per month) Varying customer demand Tight 1-1 integration between PLM, MES, Inventory, Costing, Sales & Distribution Lack of process visibility on business translation 6

7 Longer lead time to implement the process Dependency on human manual processes & information from a tangle of ERP, SCM, CRM, PLM & legacy application Solution Approach: Process Orchestration through Biz talk server,.net web service Component (SOA/WOA) Provides a Integrated system through FraME for integrating PLM, MES, Costing, Inventory & sales & distribution Managing & monitoring the process execution Solution Approach: Process Orchestration through Biz talk server,.net web service Component (SOA/WOA) Provides a Integrated system through FraME for integrating PLM, MES, Costing, Inventory & sales & distribution Managing & monitoring the process execution Benefits: Eliminate manual Change creation Full audit trail for changes FraME helps to reduce the waste of inappropriate processing Achieves a seamless flow between work centers and helps to improve customer service and slash inventories and their associated costs Reduce cycle time parallel and serial workflow processing Automatic user signoff alerts Automatic data update/creation upon release Non value added elimination ($960k per annum) Error notification is notified before the error occurs through real time dashboard thereby helping to reduce the support cost 7

8 How can I help you? Hello, I m from HCL!. We work behind the scenes, helping our customers to shift paradigms & start revolutions. We use digital engineering to build superhuman capabilities. We make sure that the rate of progress far exceeds the price. And right now, 60,000 of us bright sparks are busy developing solutions for 500 customers in 23 countries across the world. 9