JürgenKletti(Ed.) ManufacturingExecutionSystems–MES JürgenKletti(Ed.) Manufacturing Execution Systems – MES With100Figures 123 Editor Dr.-Ing.JürgenKletti(Ed.) MPDVMikrolabGmbH Römerring1 74821Mosbach Germany [email protected] LibraryofCongressControlNumber:2007923512 ISBN 978-3-540-49743-1 SpringerBerlinHeidelbergNewYork Thisworkissubjecttocopyright.Allrightsarereserved,whetherthewholeorpartofthematerial isconcerned,specificallytherightsoftranslation,reprinting,reuseofillustrations,recitation,broad- casting,reproductiononmicrofilmorinanyotherway,andstorageindatabanks.Duplicationof thispublicationorpartsthereofispermittedonlyundertheprovisionsoftheGermanCopyrightLaw ofSeptember9,1965,initscurrentversion,andpermissionforusemustalwaysbeobtainedfrom Springer.ViolationsareliableforprosecutionundertheGermanCopyrightLaw. SpringerisapartofSpringerScience+BusinessMedia springer.com ©Springer-VerlagBerlinHeidelberg2007 Theuseofgeneraldescriptivenames,registerednames,trademarks,etc.inthispublicationdoesnot imply, even in the absence of a specific statement, thatsuch names are exempt from the relevant protectivelawsandregulationsandthereforefreeforgeneraluse. Typesetting:bytheauthor Production:LE-TEXJelonek,Schmidt&VöcklerGbR,Leipzig Cover:FridoSteinen-Broo,eStudioCalamar,Spain Printedonacid-freepaper 68/3100/YL-543210 Foreword The transformation of the classic factory from a production facility into a modern service center has resulted in management problems for which many companies are not yet prepared. The economic efficiency of modern value creation is not a property of the products but rather of the process. What this means is that the decisive potentials of companies are to be found not so much in their production capability but in their process capability. For manufacturers the requirement for process capability, which has in the meantime become the basis of the certification codes, gives rise in turn to the requirement that all value-adding processes be geared to the process result and thus to the customer. A necessary condition of process transpar- ency is the ability to map the company's value stream in real time, without the acquisition process involving major outlay – a capability which is be- yond the dominant ERP systems. Today modern manufacturing execution systems (MES) can offer real- time applications. They generate current and even historical maps for pro- duction equipment and can thus be used as a basis for optimization proc- esses. As early as the beginning of the 1980s work started on methods of this kind which were then known as production data acquisition or ma- chine data collection. But while the main emphasis in the past was on achieving improvements in machine utilization, today the concern is pre- dominantly to obtain real-time mapping of the value stream (supply chain). Here the increasing complexity of production calls for a holistic view of production and services equipment and facilities: detailed planning, status detection, quality, performance analysis, material tracking and so on have to be registered and displayed in an integrated manner. In the mid-1990s the concept of the manufacturing execution system developed in the USA from out of these exigencies. A non-profit organiza- tion with the name of MESA (Manufacturing Execution System Associa- tion) started standardizing these applications and thereby raised three ap- plication layers of a production facility into a principle. MESA defines the level of production itself, the level of production management (in other words, MES), and the level of corporate management. Further works of standardization relating to this subject area are already in the process of development. Accordingly, an ISA S95 has been approved, VI Foreword whereby NAMUR, an association of process manufacturers, has come up with its own guideline for its own particular area of manufacturing. Very recently too the Verein Deutscher Ingenieure (VDI) has picked up this topic and is working on issuing a guideline tailored to the particular concerns of European manufacturers. The expectations placed upon a manufacturing execution system for in- creasing performance are correspondingly high. The practitioner will have a particular interest in topics such as TQM, SIX Sigma, operations plan- ning or optimized material movements. Even today the growing interest in this area is indicated by the increas- ing use of the term “MES” in specialist literature and market surveys not to mention in work on standardization in which a number of committees are involved. The term MES should be methodically systematized in order to give manufacturers the broadest overview possible of the capabilities and the different practical possibilities of an MES and thus put them in a position of exploiting this overview to orient themselves within the broad supply of goods to the market. In the present book, experienced specialists in the field throw detailed light on different aspects of an MES without which it is not possible to run a modern company profitably today. Gaining control of the processes is more and more becoming a central requirement for companies if they are to be able to produce profitably even in a location such as Germany. Professor Johann Löhn President of the Steinbeis-Hochschule Berlin Government commissioner for technology transfer Baden-Württemberg Table of contents 1 New ways for the effective factory...................................................... 1 1.1 Requirements for tomorrow’s manufacturing............................. 1 1.2 Production structures.................................................................. 4 1.2.1 Orientation towards metrics........................................... 4 1.2.2 Control methods............................................................. 5 1.2.3 Combinations of production structure and control method......................................................... 7 1.2.4 Weaknesses in traditional PPS systems.......................... 7 1.2.5 Function levels............................................................... 8 1.2.6 Types of production....................................................... 10 1.3 Classic IT support in production................................................ 11 1.4 Manufacturing Execution Systems (MES)................................. 13 1.4.1 Emergence of the MES concept..................................... 13 1.4.2 Current standards........................................................... 17 1.4.3 The ideal MES................................................................ 23 1.4.4 Technical requirements.................................................. 27 1.5 Vertical and horizontal integration............................................. 29 1.6 Use of an MES system in the company...................................... 34 1.6.1 Organizational requirements.......................................... 34 1.6.2 Technical requirements.................................................. 34 1.6.3 Economic efficiency....................................................... 34 1.6.4 Support for CIP and current certifications..................... 35 1.6.5 Definition and tracking of objectives............................. 36 1.7 Practical examples of potential benefits..................................... 37 2 MES for process capability................................................................. 41 2.1 Economic efficiency as a process property................................. 41 2.1.1 The process-oriented approach of ISO 9001/TS 16949................................................... 42 2.1.2 The process potential in figures..................................... 43 2.2 The process capability of the organization................................. 44 2.2.1 Identification of systematic errors.................................. 45 2.2.2 Systematic failure processing......................................... 46 2.2.3 Tracking corrective action.............................................. 47 VIII Table of contents 2.3 Process capability in collaboration.............................................. 48 2.3.1 Wasted work................................................................... 48 2.3.2 Operational target agreements........................................ 50 2.4 Process capability of information flows...................................... 50 2.4.1 The company as a paper factory..................................... 51 2.4.2 Interfaces without value generation................................ 51 2.4.3 The way to paperless production.................................... 52 2.5 The process capability of flow control........................................ 54 2.5.1 Deterministic control....................................................... 54 2.5.2 Control with feedback (closed-loop control).................. 55 2.6 Summary..................................................................................... 58 Literature................................................................................................ 60 3 Added value from software.................................................................. 61 3.1 The company as information system........................................... 61 3.1.1 Information as a production factor.................................. 61 3.1.2 Re-engineering and integration....................................... 62 3.1.3 Information processing in production............................. 63 3.1.4 Machines as information-processing systems................. 64 3.2 MES in the capital goods industry.............................................. 65 3.2.1 Characteristics of the capital goods industry.................. 65 3.2.2 MES in the IT software landscape.................................. 66 3.2.3 MES in the technology life cycle.................................... 67 3.2.4 MES as seen by the user................................................. 69 3.2.5 MES as seen by the market............................................. 70 3.3 Preparations for MES-implementation........................................ 71 3.3.1 Identification of objectives............................................. 72 3.3.2 Systematic process development..................................... 72 3.3.3 Estimation of a return on investment.............................. 73 3.3.4 System tuning.................................................................. 74 3.3.5 Introduction of MES in the company.............................. 75 3.3.6 Operation of the MES solution....................................... 76 3.4 Innovative technologies in the MES environment...................... 76 3.4.1 The digitized factory....................................................... 76 3.4.2 The digital factory........................................................... 77 3.4.3 The factory with real-time capability.............................. 78 4 MES: the new class of IT applications................................................ 81 4.1 Introduction and motivation........................................................ 81 4.2 The current situation in the manufacturing company.................. 82 4.2.1 Tools and systems for the operative level....................... 82 4.2.2 Manual information procurement and other tools........... 84 4.2.3 Problems in bringing together the data........................... 86 4.3 The situation as it ought to be..................................................... 86 4.3.1 Gapless automated data acquisition................................ 87 4.3.2 The information point for production............................. 88 Table of contents IX 4.3.3 The concept of the “manufacturing cockpit”................. 89 4.3.4 Escalation management and workflow........................... 95 4.4 Outlook and further development of MES systems.................... 97 Literature................................................................................................ 98 5 Building an MES system..................................................................... 99 5.1 Software architecture of an MES system.................................... 100 5.1.1 Basic functions............................................................... 101 5.1.2 Data layer....................................................................... 103 5.1.3 Application layer: business objects and methods........... 104 5.1.4 Process mapping............................................................. 105 5.1.5 The advantages of ESA architecture for MES systems............................................................ 106 5.2 Interfaces of an MES system...................................................... 107 5.2.1 Interfaces with higher-level systems.............................. 108 5.2.2 Interfaces for horizontal integration............................... 111 5.2.3 Interfaces with production facilities............................... 111 5.3 User interfaces of an MES system.............................................. 114 5.3.1 Technologies for user interfaces.................................... 114 5.3.2 User interfaces for configuration, monitoring and reporting.................................................................. 115 5.3.3 User interfaces for data collection.................................. 116 5.4 Outlook....................................................................................... 117 6 Integrated production management with MES................................. 119 6.1 MES systems make production management possible............... 119 6.2 The MES model.......................................................................... 119 6.3 Data analysis: information in an MES system............................ 121 6.4 Operating resources: machine or installation section................. 122 6.4.1 Order/operation.............................................................. 123 6.4.2 Material.......................................................................... 123 6.4.3 Resources and production tools..................................... 124 6.4.4 Process values................................................................ 124 6.4.5 Personnel........................................................................ 125 6.4.6 Inspection and testing characteristic............................... 125 6.5 MES data acquisition functionality............................................ 126 6.5.1 Data acquisition terminal equipment.............................. 127 6.5.2 Information for the worker............................................. 129 6.5.3 Modularity supports the diversity of data acquisition dialogs.......................................................... 131 6.5.4 Plausibility in the data acquisition process..................... 132 6.5.5 Which interfaces with the process are best used?.......... 133 6.5.6 Data correction in the MES system................................ 134 6.5.7 Availability and reliability of the MES system.............. 134 X Table of contents 6.6 MES information for production management............................ 135 6.6.1 Transparency due to MES actuality................................ 136 6.6.2 User-focused analyses..................................................... 137 6.6.3 Production-related target definition................................ 138 Literature................................................................................................ 139 7 Detailed planning and control with MES........................................... 141 7.1 Overview and goals..................................................................... 141 7.1.1 Incorporation of detailed planning and control............... 141 7.1.2 Tasks of detailed planning and control........................... 143 7.2 Use of MES for detailed planning and control............................ 144 7.2.1 Overview......................................................................... 144 7.2.2 Dealing with primary capacities in MES........................ 146 7.2.3 Modeling the processes in the MES................................ 149 7.2.4 Personnel: the especially valuable resource.................... 152 7.2.5 Modeling technological aspects...................................... 152 7.2.6 Strategies for resource allocation.................................... 154 7.2.7 Conflict resolution by simulation and optimization........ 156 7.2.8 Monitoring order execution............................................ 160 7.2.9 Reactive planning with MES.......................................... 161 7.3 Management of the means of production (resources)................. 162 7.3.1 Status management......................................................... 164 7.3.2 Anonymous and individualized resources...................... 165 7.4 Summary..................................................................................... 166 8 Quality assurance with MES............................................................... 169 8.1 Quality in practice....................................................................... 169 8.2 Planned quality............................................................................ 170 8.2.1 Quality master data in an MES....................................... 171 8.2.2 Proactive defect prevention with FMEA........................ 172 8.2.3 Inspection and testing planning: the foundations of product quality............................................................ 172 8.2.4 Inspection equipment: reducing measurement uncertainties.................................................................... 175 8.2.5 Supplier rating: optimizing the procurement process..... 176 8.2.6 Setting up workflows with escalation scenarios............. 177 8.2.7 Quality planning within production preparation............. 178 8.3 Integrated quality......................................................................... 180 8.3.1 Quality via information management.............................. 181 8.3.2 Securing supplier quality................................................ 181 8.3.3 In-process quality assurance........................................... 182 8.3.4 Optimization of inspection equipment monitoring......... 183 8.3.5 Transparent complaints management.............................. 184 Table of contents XI 8.4 Documented quality.................................................................... 185 8.4.1 Networking of information............................................ 186 8.4.2 Using quality data appropriately.................................... 187 8.4.3 Traceability.................................................................... 190 8.5 Analyzed and evaluated quality.................................................. 192 8.5.1 Potential for improvement in production....................... 193 8.5.2 Learning from complaints.............................................. 194 8.5.3 Six Sigma: putting a stop to waste................................. 195 8.5.4 Quality information: added value in the MES................ 196 9 Personnel management with MES..................................................... 199 9.1 Overview.................................................................................... 199 9.2 Staff work time logging.............................................................. 200 9.2.1 Tasks of staff work time logging.................................... 200 9.2.2 Time management in the MES or ERP system.............. 201 9.2.3 Flexibilizing work hours................................................ 202 9.3 Motivation and personnel management...................................... 204 9.3.1 Performance- and bonus-based wages........................... 204 9.3.2 Employee qualifications................................................. 206 9.4 Short-term manpower planning.................................................. 206 9.4.1 Vacation and shift planning........................................... 207 9.4.2 Checking labor capacities during detailed planning....... 208 9.4.3 Allocating employees to work centers........................... 209 9.5 Security in the manufacturing company..................................... 210 9.6 Outlook....................................................................................... 211 Literature................................................................................................ 212 10 MES with SAP...................................................................................... 213 10.1 Motives....................................................................................... 213 10.2 Integration of the MES into the SAP environment..................... 214 10.2.1 Development of the MES in SAP history...................... 214 10.2.2 Requirements for an MES in the SAP system environment........................................................ 215 10.2.3 Representation of levels in a manufacturing company... 216 10.2.4 Corporate processes in mySAP ERP and the MES system....................................................... 217 10.3 MES as an integrated solution in the SAP system...................... 221 10.3.1 Importance of SAP NetWeaver for integration of the MES..................................................................... 222 10.3.2 Interfaces with mySAP ERP applications...................... 225 10.3.3 Integration of MES functions via the SAP portal........... 228 10.4 Support for SAP’s Adaptive Manufacturing initiative............... 230 10.4.1 Scalability of the MES solution..................................... 230 10.4.2 MES for horizontal integration...................................... 231