Modern Industrial Engineering - Industrial Engineering through MES Data

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Recent Information

19.9.2023

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Search MES Data Analytics

https://www.linkedin.com/advice/0/what-latest-trends-innovations-mes-data-analysis-reporting

Added by me in the above post.

Narayana Rao KVSS

Professor (Retired), NITIE - Now IIM Mumbai - Offering FREE IE ONLINE Course Notes

Process plan needs to be fed in detail into MES to execute each step in the plan. The process has to be performed at each work station as per plan. All the inputs required at the work station are to be made available by persons or machines concerned at the time instant the process has to start. The time stamps at each work station will record the time at which the task at the work station is started and the time at which it is completed. This time for each cycle can be compared with standard time or allowed time. Delays can be found out from it from this data. Delay elimination is an important task for the managers and supervisors as well as production planners and controllers. Improvements by ind.  engineers have to be recorded in plans.

https://www.mastercontrol.com/gxp-lifeline/manufacturing-data-analysis-software-insights/

Advanced Analytics in Batch Production

You can quickly identify batch production issues with outlier detection and alerts. The manufacturing data analysis software completes all the steps necessary to identify anomalies and then provides the analysis information. 

Step execution duration and outlier detection.

Pattern detection in production record exceptions – Lets you figure out if there’s a recipe or combination of parameters that can cause more record exceptions than normal.

Seasonality detection of rejections in production records – Enables you to determine if there’s a certain time of year when you experience more than the usual number of rejections.

https://www.mastercontrol.com/gxp-lifeline/manufacturing-insights-data-analytics/

The three types of analytics in manufacturing.

#3: Prescriptive Manufacturing Insights

At this level of MES analytics, the program makes suggestions based on the plans and execution data. These suggestions help your manufacturing processes become more efficient and effective.  Prescriptive analytics recommend best practice for maximum benefit. You’ll know which combination of employees can give you the highest quality batch with the highest yield and fewest defects. When there are defects,  the system can perform a root cause analysis and tell you what the problem was. A lot of the legwork that humans do now can be done by these advanced programs, which lets the humans in manufacturing focus on more meaningful work. 

https://www.forbes.com/sites/forbestechcouncil/2022/09/29/mes-transformation-part-3-combining-the-power-of-iiot-with-descriptive-analytics/

https://www.mceneryautomation.com/case-study/brewing-mes-standard

https://www.orbis.de/en/sap-orbis-solutions/analytics-mes-dashboard.html

https://www.ge.com/digital/lp/gartner-magic-quadrant-manufacturing-execution-systems-mes

https://www.planettogether.com/blog/data-driven-quality-management-and-process-improvement-in-pharmaceutical-manufacturing

https://www.factbird.com/

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MES for Manufacturing Planning, Scheduling and Dispatching

The MES is a central strategic tool for implementing the requirements of the factory of the future. MES can provide Knowledge and Knowledge Management for Process Chart Based Industrial Engineering.

Industrial Engineering and MES Data

Industrial engineers now have the MES data to access and improve processes. The method of preparing process charts and operation details by direct observation on the shop floor  was developed by Frank Gilbreth and standardized by ASME. Now in the age of digitization, industrial engineer can  get process related information from manufacturing information systems. Manufacturing execution system (MES) is an information system that interacts with lower systems that directly control equipment and directs them to specific tasks as per the orders sent to it by the ERP system. MES also records actual execution of the operation instruction at each equipment and work station. Industrial engineers can examine MES data to understand the process and examine it for improvement. Problems encountered in process and alternatives used by the plant personnel to temporarily overcome the problems are also recorded in the data presenting industrial engineers the opportunity to make required improvements in the process.

MES data provides an approach for process improvement for industrial engineers.

Data Model for Manufacturing Execution System (MES)  - Note

MES Data - MES Brochures and Web Pages

https://www.mpdv.com/en/products-solutions/mes-hydra/processdata/

Keep an eye on process values and detect trends!

Superior products are often manufactured using complex processes which require the utmost precision. Adhering to production parameters like temperature, pressure or flow rates, and evaluating statistics aimed at continuous improvement guarantee high production quality and low scrap rates.

Benefits

Increased process stability through correlation of recorded data with orders, articles, material batches, and more

Reduced scrap due to continuous monitoring of defined process parameters and early detection of trends

Cost savings through multiple use of shared data (e. g. for quality assurance)

Compliance with specifications for complete documentation of the manufacturing process

Support of condition-based maintenance strategies

Process data collection 

Process Data Collection

While the continuous control of production parameters, process values and their recording can now be taken over by sensors, modern machines and plant controls (PLC), the HYDRA module Process Data (PDV) offers functions that go far beyond this. The complete integration of all MES applications on the basis of a central database allows for the correlative examination of other data. The comparison of data to orders, articles, material batches or tools and process values makes a valuable contribution to optimize your production. For example, limit value violations can be detected relating to current orders or manufactured articles. The early detection of trends enables timely intervention and countermeasures. HYDRA PDV transfers process values via a standard interface (e. g. OPC): The collected data can also be used as an input parameter for production-related quality inspections.

Many business units across the enterprise can benefit from an MES system. Our ROI Analyzer reveals the untapped potentials that are still hidden within your production processes.  

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COLLECT, ANALYZE AND OPTIMIZE

Once your processes are in place and your MES system is at work, you can maximize efficiency, yield and quality by collecting and analyzing process data. EZ-MES will allow you to have a seamless integration of your Process Data acquisition, as well as live reports like Product Tracking, WIP and Inventory. This will enable you to make well informed decisions that will improve your bottom line. 

USE EZ-MES TO COLLECT DATA

The real time browser based Manufacturing Execution System EZ-MES collects process data as parts travel through different manufacturing steps. Critical travel data such as start time, end time, resources used, yield, drop outs are automatically logged at a very granular level. 

Data generated by your manufacturing process can be collected via manual input or in an automated way.

In case of manual data collection, EZ-MES has build-in a number of pre-formated and configurable User Interface elements. Forms using such user interface elements allow seamless input of data by humans while supporting that the date is entered correctly. This is be done by using pre-configured radio buttons, dropdown boxes and input fields with validation checks defined via regular expressions.

Many tools in today's manufacturing environment support data collection, such as barcode-readers, forms, equipment, electronic handheld devices and others. Data generated by those and by equipment using sensors, can be automatically feed to EZ-MES by using its open Application Programming Interface (API). This open API allows software tools for automated measurements to access the data and core functions in EZ-MES. 

ANALYZE COLLECTED DATA

EZ-MES contains a number of pre-formatted reports. For the purpose of data analysis, EZ-MES contains 'out of the box' Statistical Process Control (SPC) Reports. SPC is an industry-standard method for measuring and analyzing data for quality during the manufacturing process. Product, Part and Process measurements are gathered by EZ-MES during manufacturing. This data is then plotted on a graph with pre-determined control limits. 

Results that falls within the control limits indicates that everything is operating as expected. Any variation within the control limits is considered to be acceptable due to natural variation in the manufacturing processes. If data consistently falls outside of the control limits, then this indicates that something within the process is likely not running as it is supposed to do. Repairs need to fix the issue before serious defects and possible escalations occur.

OPTIMIZE YOUR PROCESSES

The immediate and real time use of production data collection and analyses is to detect acute production problems or even faults leading to expensive recalls, if not detected in time.  Next to this short term need, there is an obvious and on-going mid- and long term need to further improve both processes and products and reduce costs.

As manufacturing processes are soft configured in EZ-MES instead of being hard-coded, rapid prototyping changes in EZ-MES is relative fast and easy to do, as no programming skills are needed. EZ-MES has an optional Sandbox version which allows you to first try out and simulate changes in your manufacturing processes and in your vertical and horizontal integration of flows. You can dry-run these changes and if accepted, make them available to the Live version of your EZ-MES application. As EZ-MES is a realtime browser application, your changes are immediately deployed to all users, without any need for local software updates.

After the deployment of the changes, you can start collecting and analyzing production data. To evaluate the real world impact of the changes you made. 

https://eazyworks.com/solutions-collect-analyze-and-optimize

Process Data Management, part of ABB Ability™ Manufacturing Execution System for pulp and paper

Configuring your data sources

Your goal: valuable process data seamlessly retrieved from fragmented control systems, interfaced with other data sources, ready to communicate towards the Cloud and the shop floor in real time. 

Our solution: Process Data Management, part of ABB Ability™ Manufacturing Execution System for pulp and paper

ABB has the right combination of domain-specific expertise and knowledge of both IT and OT infrastructure to ensure that your data management approach is closely aligned to your business strategy.

We know how to properly label, model and structure data specific to the pulp and paper operations, how to store, compute and stream high volumes of data securely and cost effectively.

https://new.abb.com/pulp-paper/abb-in-pulp-and-paper/systems/collaborative-production-management-products/process-data-management

Transforming the pulp and paper industry through systematic data management

27 Apr 2021

John Schroeder 

https://www.abb-conversations.com/2021/04/transforming-the-pulp-and-paper-industry-through-systematic-data-management/

Good Presentation - MES, Operational Excellence, Data Analytics and Manufacturing Intelligence

https://www.slideshare.net/BoraSusmaz/mes-operational-excellence-data-analytics-and-manufacturing-intelligence

Sanofi: Designing a Data Management Strategy for the Future

May 12, 2021 | Patrick Nadolny

https://www.veeva.com/blog/sanofi-designing-a-data-management-strategy-for-the-future/

https://pdfslide.net/healthcare/sanofi-aventis-analytics-journey-transforming-big-pharma.html

Selecting Cutting Data Tests for Cutting Data Modeling Using the Colding Tool Life Model

Procedia CIRP, Volume 72, 2018, Pages 197-201

https://www.sciencedirect.com/science/article/pii/S2212827118301355

Applying data of historical defects to increase efficiency of rework in assembly

Procedia CIRP, Volume 72, 2018, Pages 255-260

https://www.sciencedirect.com/science/article/pii/S2212827118301902

Big data analytics for operations management in engineer-to-order manufacturing

Procedia CIRP, Volume 72, 2018, Pages 209-214

https://www.sciencedirect.com/science/article/pii/S2212827118302531

Pin Point MES

THE MES SOLUTION that helps you reach your productivity and quality goals.

https://www.pinpointinfo.com/blog/manufacturing-process-improvements-data-analytics

https://www.pinpointinfo.com/blog/mes-productivity-case-study

https://www.pinpointinfo.com/blog/lean-and-mes-minimize-waste-improve-productivity

Boost Error-Proofing in Manufacturing with an MES Solution

Jarda Smrz, President, Pinpoint

April 30, 2020

https://www.pinpointinfo.com/blog/boost-error-proofing-in-manufacturing-mes-solution

https://www.pinpointinfo.com/blog/operator-driven-production-data-manufacturing-success

https://www.pinpointinfo.com/blog/uncovering-the-hidden-factory

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MES Softwares - Interesting Information

SAP ME by SAP

https://en.t-h.de/case-studies/overview.html

Automotive: Transparent Production with real-time Monitoring

With SAP Manufacturing Integration and Intelligence (SAP MII) in connection with Best Practice solutions, supplied by Trebing + Himstedt and integrated into the application, the components supplier WITTE Automotive seamlessly connects its shop floor systems with SAP ERP. This enables the company to monitor manufacturing processes in real time and to maintain a transparent, comprehensive view of its key data at any time. Both are vital leverages to optimize production processes and render them more cost-efficient.

https://en.t-h.de/case-studies/plant-performance-management.html

Honeywell Connected Plant

by Honeywell

https://www.honeywellprocess.com/en-US/online_campaigns/connected_plant/Pages/home.html

https://www.youtube.com/watch?v=QUjisqHmok4

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Oracle Manufacturing Cloud

by Oracle

https://www.oracle.com/in/scm/manufacturing/

https://docs.oracle.com/en/cloud/saas/supply-chain-management/20b/faumf/production-process-design.html

https://www.wipro.com/en-IN/applications/real-time-mes-putting-precision-into-your-plant/

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Siemens Opcenter

by Siemens

https://www.industrialautomationindia.in/articleitm/8474/Scanfil-selects-Siemens-Opcenter-to-digitalize-operations/articles

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TrakSYS

by Parsec

https://fdocuments.in/document/traksys-customer-case-study-aps-group.html

https://fdocuments.in/document/traksys-customer-case-study-aps-group.html

https://www.youtube.com/watch?v=BO0HgEOxQiQ

Information Technology for Manufacturing: Reducing Costs and Expanding ...

By Kevin Ake, John Clemons, Mark Cubine, Bruce Lilly

https://books.google.co.in/books?id=NZdw2971DSEC

MES Modules - MPDV

Shop Floor Data

Machine Data

Shop Floor Scheduling

Dynamic Manufacturing Control

Tool & Resource Management

Material & Production Logistics

Tracking & Tracing

Energy Management

DNC & Configuration Data

Process Data

In-Production Inspection

Incoming Goods Inspection

Complaint Management

Test Equipment Management

FMEA

Premium & Incentive Wages

Personnel Scheduling

Time & Attendance

Personnel Time Management

Access Control

https://www.mpdv.com/en/products-solutions/mes-hydra/shop-floor-data/

Gartner's Magic Quadrant for MES

2021 - https://mes.criticalmanufacturing.com/2021-gartner-magic-quadrant/

Videos on MES

Critical Manufacturing

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https://www.youtube.com/watch?v=PLntjUFMLk8&t=3s

https://www.youtube.com/watch?v=5zoUit97Rx4&list=UULh-scVR4DHPfY1GrnufQnw

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More Videos

RSA Solutions

https://www.youtube.com/watch?v=5FWWoCz90Y8

https://www.youtube.com/watch?v=Rz02m0NiKZ0

Corso Systems

https://www.youtube.com/watch?v=g2Zx3gYiSuM

Mahindra Presents MES for Automotive Operations

•20 Oct 2015

MES implemented at Chakan MVML

Rockwell Automation

29.8K subscribers

Mahindra provides a detailed system tour of their Rockwell Software ProductionCentre MES for automotive manufacturing operations and enterprise systems.

https://www.youtube.com/watch?v=o8j2udvlMyU

Brock Solutions

https://www.youtube.com/watch?v=m38GaSbzDqs

MES and Seven Waste Model

An interesting explanation of seven wastes by Deloitte Insights

Image source: https://www2.deloitte.com/xe/en/insights/focus/industry-4-0/digital-lean-manufacturing.html  - Good content on the concept of digital lean

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MES Software Helps Plants Integrate Cross-Functional Platforms

Islands of automation are giving way to plant-wide (even enterprise-wide) efforts that yield performance analysis and front-office profit maximization.

11 April 2008

Evolving Price/Performance of DCS - PLCs

“In the mid-1980s,  Serial No. 1 of the Rosemount [now Emerson Process Management] RS3 [DCS],  gave 40-megabytes of hard drive to work with and  cost was $2 million. 

Today, a single programmable logic controller (PLC) can perform the same function  and the cost of even a high-end PLC is about $500. More impressive: PLCs  today handle motion, motor and process loop controls that a decade ago required multiple vendors, tools, parts and training that far exceeded the hardware cost.

Automation systems is standardization

A key enabler of today’s automation systems is standardization.  ISA-88 and ISA-95 consist of common terms and definitions for manufacturing functions; common process models that map real-world plant processes and data flows; and programming conventions shared by automation professionals. As such, they serve both as templates for training as well as technology development. Some of their key features:

ISA-88 and allied efforts (such as Make2Pack for packaging) address most production environments found in food plants, including automated product changeovers. This standard first affected first-tier control software such as human-machine interface (HMI) and supervisory control and data acquisition (SCADA) software and grew with batch and manufacturing execution systems (MESs).

ISA-95 is a control-to-enterprise standard built upon ISA-88. It  maps workflows between production, packaging, quality and maintenance. It broadens the effectiveness of MES-level models with extensions from production to functions throughout operations and up to the ERP level. 

Many companies are finding significant savings in more rapid integration of their SAP systems with factory processes via the  standard interface provided by  ISA-95. 

Smithfield refined its  systems using  Rockwell’s software conformance to such standards in a greenfield plant. The strategy now is being implemented gradually across all plants. It integrates plant applications with the ERP system and the web services make this information available to remote managers monitoring plant-by-plant performance levels. Sales personnel can track orders to levels of partial completion.

Executing a command performance

Most companies with revenues above $250 million are using MES systems at some level. 

MES can be seen as having has two tiers of benefits: production management and performance management. Standard features typically include data collection and event-driven alerts for operator intervention such as clean-in-place (CIP), hazards analysis and critical control points (HACCP) programs or material replenishment.

Systems rise to the level of performance management when they include modules for or integrate with functions outside production and incorporate deeper analytical functions such as optimal equipment effectiveness (OEE).

The practice of OEE is accompanied by aggregated data presented as key performance indicators (KPIs), such as a single-value index or percentage of a production line’s performance against an ideal goal. It’s one of many uses for KPIs that can be presented in dashboard-style values, dials or graphic bars.

Each KPI, wherever it is displayed, should be role-specific to the operator, supervisor or manager using it. According to Walt Staehle, an ex-Kraft Foods manufacturing executive who installed MES, laboratory and other systems across 50-plus Kraft plants during this 20-plus years there,  Kraft recouped $1.6 million by reducing variability in raw materials-to-finished goods conversion and improving asset utilization by using a simplified (uptimeonly) version of OEE as part of a collaborative, real-time performance management strategy. 

Key performance indicators are measured and used to run  businesses and shop floors in many companes.

The economic justification for plant automation is the same, whether a plant uses PLCs or a DCS and whether the plant is dedicated to candy bars or corn wet milling.

https://www.foodprocessing.com/articles/2008/083/

OEE Metrics Reveal Return on Investment

Plant operators are proving the financial value of their automation investments with measurable data on overall equipment effectiveness (OEE) and other hard metrics.

Rob Spiegel, Apr 1st, 2005

https://www.automationworld.com/products/software/article/13303509/oee-metrics-reveal-return-on-investment

Six Sigma Takes Root in Rich MES Data

by Charles Rastle and Julie Fraser

Quality Digest Magazine, July 2004

Author: Charles Rastle is an industry strategic marketing manager for Rockwell Automation’s Global Manufacturing Solutions group.

https://www.qualitydigest.com/june04/articles/04_article.shtml   (23 November 2020)

Updated on 20.9.2024,  19.9.2023, 29.12.2021,  19.9.2021, 8.8.2021, 29.4.2021 1 Feb 2021, 8 December 2020

First published on 22 November 2020