10. Trickle Down Theory Level 3 Manufacturing Control Systems Area Supervision, Production Scheduling, Reliability Assurance Levels 2,1,0 Batch Control Systems Discrete Control Systems Continuous Control Systems What is MES? Level 4 Business Logistics Systems Plant Production Scheduling and Operational Management
13. Production Capability Information Production capability and capacity definition, is specific to an area, process cell, production unit, assembly line. Production equipment status Maintenance information on production equipment, including information not related to the production capability Maintenance Production Capability Information Information Scheduled Production equipment outages Scheduling Capability Information Preventive/Predictive Maintenance Information Scheduling information on production equipment, including information not related to production capability Production Capacity (Including equipment organization and product flows) What is MES?
14. Production Information Inventory Production Information Information Scheduling Information What is MES? Production information, is specific to an area, process cell, production unit, assembly line. (Batch Journal, log, …) Production Material Information Information on all inventoried material and equipment. Production Schedule and Production Performance Scheduling information on production Production Line Item Information
44. Loosely coupled functional modules across manufacturing with the ability to leave legacy systems in place
45. Process centric approach using appropriate technology as needed through combination of customization and extension of existing systems and incorporating new technologies/applicationsThe Evolutionary Approach Evolution not Revolution 14
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47. Pay for what you use – Smaller Technology Purchases
101. Integrating functional data across business units and plants23 Build Capabilities to Reach Best In Class Charting a Course
102. Develop capabilities that reflect Business Goals and Objectives 24 Build Capability Pyramids Best In Class Laying the Foundation Goal Integration Automation Foundation
103.
104. Determine Automation Requirements25 Determine Low Hanging Opportunities A successful man is one who can lay a firm foundation with the bricks others have thrown at him. - David Brinkley Laying the Foundation
105. Scenario: Operators at the Acme Drug Company add to the Batch Record at Compounding by physically attaching a paper trend chart for environmental conditions. On average, three incidents per Quarter occur where the incorrect chart data was associated with a Batch. Of those incident batches, one batch in three cannot be resolved and is lost. Costs: Annual time and material 4 quarters * 3 incidents = $15K-$50K 4 quarters * 1 batch/quarter = $1M - $5M Opportunity $1M – $6M A Genealogy MOM Capability Appears to be a Viable Candidate Project. 26 Identifying the Target Laying the Foundation
106. 27 Map MOM Activities to Capabilities Laying the Foundation
107. Hold Workshop(s) for Selected Capability 28 No one wants advice, only collaboration - John Steinbeck Build the Pyramids
119. Record and Associate production data with Batch Record31 Genealogy Automated Data Collection Build the Pyramids
120. Using or expanding the Automation functions you already have is a smart way to achieve MES functionality What’s in the Backyard? 32 Build the Pyramids
133. Use ROI to Justify Next Brick37 Implement and Evaluate Plans are only good intentions unless they immediately degenerate into hard work. - Peter Drucker Build the Pyramids