trends and solutions in mes and operations management g gorbach arc orlando 2008
Post on 29-Nov-2014
18.713 Views
Preview:
DESCRIPTION
TRANSCRIPT
Global ManufacturingGlobal ManufacturingGlobal Manufacturing
Trends and Solutions in
Global Manufacturing
Trends and Solutions inTrends and Solutions inMES and Operations Management
Trends and Solutions inMES and Operations Management
Greg Gorbachi idVice President
ARC Advisory Groupggorbach@arcweb.com
Today’s Business RequirementsDrive Change & Determine Real-time Enterprise NeedsToday’s Business RequirementsDrive Change & Determine Real-time Enterprise Needs
GlobalizationRapid Product InnovationProcess InnovationCollaborationS h i tiSynchronization LeanContinuous ImprovementComplianceComplianceRisk ManagementPerformanceFlexibilityyPull-based ProductionEtc.
2© ARC Advisory Group
Manufacturing Systems Have Not Kept PaceOlder Applications and IT Infrastructure Limit PerformanceManufacturing Systems Have Not Kept PaceOlder Applications and IT Infrastructure Limit Performance
Manufacturers have
3© ARC Advisory Group
not invested enough in plant floor ITSource: ARC Advisory Group
Manufacturers Are Now Investing in OMOM is an $8 Billion Market and GrowingManufacturers Are Now Investing in OMOM is an $8 Billion Market and Growing$ g$ g
4© ARC Advisory Group
Today’s Dynamic, Demanding Environment Places a Premium on Information and Synchronization
Industry Classic MES New RequirementsSemiconductor Complex Routing, Resource
Allocation Quality WIP TrackingVisibility, Analytics/Decision Support, Outsourced Manufacturing Business System SynchronizationAllocation, Quality, WIP Tracking,
etc.Manufacturing, Business System Synchronization, KPIs, Performance, Change Mgmt, Security, Electronic Manufacturing History etc.
Pharmaceutical Compliance, Quality (Direct and Enforce Production), Electronic Batch Records, Electronic Signature etc
Visibility, Analytics/Decision Support, Outsourced Manufacturing, Business System Synchronization, Performance, Change Mgmt, Security, Electronic Manufacturing History etcSignature, etc. Manufacturing History etc
Continuous Process
Collection of Apps: Optimization, Historian, Advanced Process Control, etc.
Visibility, Analytics/Decision Support, Outsourced Manufacturing, Business System Synchronization, Performance, Change Mgmt, Security, Electronic Manufacturing History, etc
A&D (Complex CAPP, Quality, Resource Allocation Visibility, Analytics/Decision Support, OutsourcedA&D (Complex Discrete)
CAPP, Quality, Resource Allocation (Operators, Workstations, Tooling, etc.) WIP Tracking, Traceability, Work Instructions, NCR Resolution, etc.
Visibility, Analytics/Decision Support, Outsourced Manufacturing, Supplier Quality Mgmt, Change Management, Security, Electronic Manufacturing History, etc
Automotive Supplier
Quality, Resource Allocation (Operators, Workstations, Tooling,
Visibility, Analytics/Decision Support, Orchestrate Inventory Replenishment by Operation,Supplier (Operators, Workstations, Tooling,
etc.) Work Instructions, Just-in Sequence Manufacturing/ Packing/ Shipping, Error-proof Packout and Labeling, etc.
Inventory Replenishment by Operation, Traceability and Recall Management, Business System Synchronization, Performance, Change Mgmt, Security, Electronic Manufacturing History, etc
Automotive OEM Visual Alarms, Stack Lights, and Marquees Line Control &
Visibility, Outsourced Manufacturing, Global Manufacturing Business System Synchronization
5© ARC Advisory Group
Marquees, Line Control & Broadcasting, Supplier Component Sequencing, etc.
Manufacturing, Business System Synchronization, Performance, Change Mgmt, Security, Electronic Manufacturing History, Traceability and Genealogy, etc
Discrete Manufacturing DynamicsRequire a Collaborative Manufacturing ApproachDiscrete Manufacturing DynamicsRequire a Collaborative Manufacturing Approachq g ppq g pp
Components &
Business Systems
Supplier Network
Components & Materials
Product Support
eCustomers
Finished Goods
Manufacturing Operations
Design, Specifications, & Mfg Processn
terp
ris
DistributionEngineeringDesign
En
6© ARC Advisory Group
Today’s Market Dynamics Demand SpeedOM Enables Real-time Performance ImprovementToday’s Market Dynamics Demand SpeedOM Enables Real-time Performance Improvementpp
ARC ‘sCollaborative Manufacturing
Manufacturing Plant
Business
InternalManufacturing Management Model
External
CustomersCRMSRM
ERP
Manufacturing Plant
eSuppliers
OMLogistics
PLMContract Manufacturer
nte
rpri
s
Production
Automation
Logistics Provider
Distributor
Retailer
En
7© ARC Advisory Group
Retailer
AssemblyPlant
Retailer
CMM Applications MapLet’s Get on the Same Page re: MES and OMCMM Applications MapLet’s Get on the Same Page re: MES and OM
Business
FINERP
HR
CustomersSuppliersCRMSCM
(SOA)T&A
TMS
CAM MPM
CAD
Operations Infrastructure
Enterprise InfrastructureGen 4
EAM
E i &
WMS
T&A
Lean/CI
HMI
MISched
etc.
CAM
Quality
MPM
Gen 3(Integrated Apps, Infrastructure, &
Connectivity)
MESOperations Management
8© ARC Advisory Group
Equipment & Automation
Production
Connectivity)
MES Gen 2MES Gen 1(Standalone, Industry-Specific Application)
(Collection of Applications)
Operations Management Definition:Operations Management Definition:
Operations Management is the management of the people, business processes, technology and capital assets involved in:
• Procuring and receiving raw materials and components- Especially as it relates to obtaining, storing, and moving
necessary materials/components in a timely manner and of suitable quality to support efficient production
• Implementing product designs, specifications, formulations, or recipes by manufacturing products- Including manufacturing process planning and validation
• Distributing these products to customers- Especially as it relates to sequencing and in-house logisticsEspecially as it relates to sequencing and in house logistics
• And for some products, supporting them through their End-of-Life
9© ARC Advisory Group
Let Business Requirements Drive Technology Solutions
CMM Model for Production ExcellenceEngineering, OM, and Resources Working TogetherCMM Model for Production ExcellenceEngineering, OM, and Resources Working Togetherg g, , g gg g, , g g
Enterprise/Business Operations
Operations M t
Operations Management
Inbound Supply Chain & Logistics
Customer Relationship
OM IT Infrastructure
Management Systems
Management
ProductionManufacturing
Outbound Supply Chain & Logistics
Product Design
OM Functionality (Apps or Services)
AutomationSystems
Production Equipment & Automation
Manufacturing Engineering
10© ARC Advisory Group
Collaborative Production Environment for Highly Flexible Manufacturing
Three Pillars of OM SolutionsSupport Business Needs with Operations-Wide Performance Three Pillars of OM SolutionsSupport Business Needs with Operations-Wide Performance pp ppp p
Infrastructure• Real-time Plant Support
Connectivity• Enterprise
Functionality• Plan Productionpp
• Technology Platform• Applications Platform• Business Processes• Security• Role-based Portals
p• Design & Engineering• Operations, Controls, &
Equipment• Supply Chain & External
Operationsd
• Execute Production• Track Product Data• Inform & Analyze• Enforce Quality• Move & Store Inventory
• etc. • Product Support Opsy
• Manage Assets• Support Product thru EOL
Operations Management
12© ARC Advisory Group
Operations Management
Source: ARC Advisory Group
Pillar 1: OM IT InfrastructurePlatforms, Processes, Portals, etc. Pillar 1: OM IT InfrastructurePlatforms, Processes, Portals, etc. , , ,, , ,
Infrastructure•Real-time Plant SupportReal time Plant Support•Technology Platform•Applications Platform•Business Processes•SecurityR l b d P t l•Role-based Portals
•etc.
13© ARC Advisory Group
Multiple Platforms Need To Collaborate
Enterprise Technology
CRMSCM
FINERP EAMContent
Enterprise gPlatform
Custom Integration
Enterprise Apps Platform
Custom Integration
Data WMS
Operations Apps Platform
PDM EquipmentDrawings
Eng. & Design Apps Platform
Operations
PAMLIMS
CPM/AutomationDataTMS
Equipment
PDM
P&IDsModels
EquipmentSpecs
Drawings
Technology PlatformEng & Design
Technology Platform
14© ARC Advisory Group
Operations PlatformEng & Design Platform
Global Manufacturing OperationsGlobal Manufacturing Operations
Design/Engineering Infrastructure
Enterprise InfrastructureOperations Infrastructure
es g / g ee g as uc u e
15© ARC Advisory Group
= Manufacturing Node = Design Node
Pillar 2: ConnectivityRequired for PerformancePillar 2: ConnectivityRequired for Performanceq o oq o o
S h i iEnterprise
Synchronization of Manufacturing with other entities
Orchestrationf B i P
OperationsConnects
Product Support
Design & Engineering
of Business Processes
Responseto dynamic demands
with:
OperationsSupply
Collaborationamong all required parties
AlignmentOperations Controls & Equipment
Chain & External
Operations
Source: ARC Advisory Group
of goals throughout the Enterprise
Visibilityof Manufacturing Information
16© ARC Advisory Group
Source: ARC Advisory Group
Typical Integration ApproachesTypical Integration Approaches
1. Enterprise Communications BusSelect Technology Platform Manage Interfaces etcSelect Technology Platform, Manage Interfaces, etc.
2. Standardize InfrastructureTools for All Integration Projectsg j
3. Operations Management Supplier SolutionAlign with Operations Management Supplier’s Chosen T h lTechnology
4. Enterprise Supplier SolutionAlign with Enterprise Supplier’s Chosen TechnologyAlign with Enterprise Supplier s Chosen Technology
17© ARC Advisory Group
Pillar 3: OM Functions/ProcessesUse Detailed, Industry-Specific List for System SelectionPillar 3: OM Functions/ProcessesUse Detailed, Industry-Specific List for System Selection
•Schedule•ProcessesPlan Production
Processes Examples
Processes•Data and Test Needs
Plan Production
•Enforce Processes•Guide Operators•Collect Data
Execute Production
•WIP Tracking•WIP Tracking•Electronic History•Traceability & Genealogy
Track Product Data
•Role-based Views•Drill-down & Analytics•Event-triggered Notification
Inform & Analyze
•CAPA•NCM•Supplier Quality
Enforce Quality
•WMS•Line-sideMove & Store Inventory•RFID
Move & Store Inventory
•Maintenance & Repair•Work Orders•Synchronize w/Operations
Manage Assets
•RMA
S d h O
24© ARC Advisory Group
•MRO•Recovery & Recycling
Support Product thru EOL
OM Functional Requirements3 of 8 Categories Partially Illustrated HereOM Functional Requirements3 of 8 Categories Partially Illustrated Hereg yg y
Category Function DescriptionProduction Planning
Schedule Management Develop and maintain short-term detailed schedule. Coordinate with input from ERP schedule or Order Management system
Production Planning
Sequence Build to Order Support 100 or more operations and multiple production lines building products according to the OEM sequenced buildPlanning building products according to the OEM sequenced build requirement. Develop …
Production Planning
Define In-Process Data Collection
Data Collection Templates shall be configurable and allow users to specify a list of rules and data items to be collected at a process step: User defined …
Production Planning
Define Workflows/Process
Create and maintain workflows that define and enforce complex procedures, standard processes, rework paths, Material Review
Enforcementp , p , p ,Board (MRB) procedures …
Production Planning
Define Workflows/Process Enforcement
Create process plans (similar to ERP routings, but much more detailed) consisting of: …
Category Function DescriptionProduction Execution
Sequence Build to Order Execution
Support 100 or more operations and multiple production lines building products according to the OEM sequenced build requirement...
Production Execution
Workflow Management/Process Enforcement
Any sequence of the following actions occur within a defined process step: • Enter Step …
EnforcementProduction Execution
Workflow Management/Process Enforcement
Ensure that all routings, assembly instructions, rework, inspection and test operations, data collection, approval/buyoff signatures, material movements,…
Production Execution
Start Processing Verification
Provide the ability to induct a lot and have it automatically go to a preparation process (e.g cleaning or inspection). This should be …
Production End Processing At or near the completion of processing on a lot the system must beCategory Function DescriptionProduct Data WIP Tracking Track work-in-process by lot, batch, or serial number or in Production
ExecutionEnd Processing Verification
At or near the completion of processing on a lot, the system must be able to check that: The correct components were consumed...Tracking
p ycombination, across all production steps and processes and locations, including …
Product Data Tracking
Sequence Build to Order Collect and associate process variable information by operation and sequence number
Product Data Tracking
Serialized Component Tracking, Genealogy, and Traceability
Support OEM requirement for complete part traceability and genealogy, all the way from material suppliers through each
f t i ti i
25© ARC Advisory Group
Traceability manufacturing operation in …Product Data Tracking
Genealogy Trace from assembly lot numbers or serial numbers to all of the component and sub-assembly lots that were used to construct those assemblies, and…
Product Data Tracking
Bulk Issue Transactions When MRP bulk-issues material to the floor and does not track consumption, the Operations Management system should not …
OM Functional RequirementsMust Include Integration & Performance RequirementsOM Functional RequirementsMust Include Integration & Performance Requirementsg qg q
Category Function DescriptionIntegration -Product Lifecycle
New Product Introduction
Define processes for prototype lots and collect detailed data for analysis. Support multiple prototyping iterations. Synchronize …
Integration -Product Lifecycle
Post-production Product Support
Provide a mechanism to feed post-production quality/defect data back into the product development cycle (design engineering and …Category Function Description
Integration -Operations, C t l &
Realtime Data -Machine Integration, B d RF M l
Integrate to plant equipment, systems, and devices as necessary to gather or share data and information required to coordinate the …
Controls, & Equipment
Barcode, RF, Manual
Integration -Operations, Controls, & Equipment
Interface to Plant Applications and Systems
Provide connectors/adapters to enable the collection of data in near-real-time from plant applications and systems such as HMI, …
Category Function DescriptionIntegration -External Operations and
Integration to Outsourced Manufacturing
Receive order status and quality information from outsource manufacturing operations and independent supplier operations to ensureOperations and
Supply ChainManufacturing Operations or Supplier Manufacturing Operations
ensure …
Integration -External Operations and Supply Chain
Integration to Customer Quality, Supplier Management, ERP, and Operations Systems
Provide real-time production status information to customer systems. Provide component/assembly identification information to customers …
Category Function DescriptionIntegration -Enterprise
Real-time Visibility Provide portlets to support real-time graphical, tabular, and drill-down display of manufacturing data in dashboards or portals such asSupply Chain Operations SystemsEnterprise display of manufacturing data in dashboards or portals such as …
Integration -Enterprise
Scenario Integration Provide a means to compose, populate, generate, and exchange messages with ERP and other business systems, based on P2B standards such as …
Category Function DescriptionSystem Performance
System Start-up, Validation, & Change Mgmt
Assess and evaluate the system in detail. Document evidence that the system operates and behaves in accordance with specifications …
System Performance
System Design and Configuration: Virtual OM System
Design and create routings, workflows, etc. based on digital virtual manufacturing model. Automatically generate OM system …
26© ARC Advisory Group
yConfiguration (FUTURE)
Thank You!
27© ARC Advisory Group
top related