Performix Inc: Implementing MES in SAP Landscape

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Performix Inc: Implementing MES in SAP Landscape

Implementing MES in SAP Landscape Sham Afzalpurkar CEO, Performix Inc. September 26 th , 2006

Introduction Sham Afzalpurkar, CEO Performix Inc About Performix A Manufacturing Execution Systems organization Developing xApps in MES space Significant Supply Chain, Manufacturing Execution &Track/Trace encounter Focus on Pharmaceuticals, Process Industries and Hi Tech Offices in Houston, Texas with advancement groups in India

Agenda Overview of MES Justifying MES Developing MES Strategy MES Architecture Integration Strategy Implementation Plan Lessons Learned

Why MES? In the most recent decade, ERP and SCM have NOT conveyed the normal profits Focus for sending MES answer for give perceivability and adaptability and viably oversee inventory network Competition has constrained quality items at lower taken a toll Integration of ERP and MES has been a test Standards such ISA 95 give the possibility to improve organization

What is Manufacturing Execution System? Co-ordinate works on the shop floor to upgrade the plant exercises Manufacturing Execution System gives powerful coordination between creation procedures and endeavor business frameworks. Layer of correspondence amongst business and control frameworks ERP MES SHOP FOOR AUTOMATION

Components of MES Core Material and Production Tracking Material Handling and Production Procedures Resource administration and assignment Production Dispatching Data Collection Extensions Compliance Quality Assurance Performance Analysis Detail Scheduling Document Management Labor Management

What is ISA 95? I nstrumentation, S ystems, and An utomation Society ( ISA ) Standard that characterizes how to connection Enterprise and Controls frameworks utilizing a Manufacturing Execution Systems (MES) layer. This standard portrays: The MES Functionality The Data base construction at the MES Level The Messages between the Enterprise framework and MES

What is B2MML? The World Batch Forum (WBF) has distributed XML outlines in view of the S95 Model - B2MML (Business to Manufacturing Markup "Hypertext" Language) B2MML-V0201-Common.xls B2MML-V0201-Personnel.xls B2MML-V0201-Equipment.xls B2MML-V0201-Material.xls B2MML-V0201-Maintenance.xls B2MML-V0201-ProcessSegment.xls B2MML-V0201-ProductionDefinition.xls B2MML-V0201-ProductionCapability.xls B2MML-V0201-ProducitonPerformance.xls B2MML-V0201-ProductionSchedule.xls

MES sellers offer arrangements that cover usefulness offered by SAP

Agenda Overview of MES Justifying MES Developing MES Strategy MES Architecture Integration Strategy Implementation Plan Lessons Learned

Justifying MES – Business Drivers Visibility of information universally Standard procedures Enable benchmarking and best practices Consistent Documentation Resource Utilization Accurate and predictable KPI Seamless Integration

Justifying MES - Benefits Increases Operational Excellence Lower Operating Costs Asset Management Reduced Total Cost of Ownership

Agenda Overview of MES Justifying MES Developing MES Strategy MES Architecture Integration Strategy Implementation Plan Lessons Learned

Manufacturing Assessment & Planning What are the business drivers? What are the hierarchical and process related issues? What ought to be done first – adjusting fabricating methodology to business system

Business Functions (S95) Enterprise Performance Reporting Level 4 Business Planning & Logistics Demand Planning Supply Chain Planning Cost Accounting Human Resource Management Sales & Distribution Material Management Production Planning Warehouse Management Maintenance Management Detail Scheduling Process Optimization Recipe Management Performance Management Process Analysis Level 3 Manufacturing Operations Resource Management Production Execution WIP Material Management Production History Quality Management Real-Time Execution Real-Time SPC Level 2 Plant Floor Control Real-Time Control Real-Time Monitoring

ERP Enterprise Performance Reporting Demand Planning Supply Chain Planning Cost Accounting Human Resource Management Sales & Distribution Material Management Production Planning Warehouse Management Maintenance Management Detail Scheduling Performance Management Process Analysis Resource Management Production Execution WIP Material Management Production History Quality Management Some PLCs Machines & Work Centers Fixed Routes, No Lot Splitting Only Ingredients Changes Real-Time Execution Real-Time SPC Real-Time Control Real-Time Monitoring Simple Discrete

ERP Enterprise Performance Reporting Demand Planning Supply Chain Planning Cost Accounting Human Resource Management Sales & Distribution Material Management Production Planning Warehouse Management Maintenance Management Detail Scheduling Process Analysis MES Thousands of parts, complex techniques, numerous items Resource Management Production Execution WIP Material Management Production History Quality Management Some PLCs Machines & Work Centers Production Lines Real-Time Execution Real-Time SPC Real-Time Control Real-Time Monitoring Aerospace and Automotive Complex Discrete

ERP Enterprise Performance Reporting Demand Planning Supply Chain Planning Cost Accounting Human Resource Management Sales & Distribution Material Management Production Planning Warehouse Management Maintenance Management numerous common assets, complex directing, numerous items MES a great many parts, complex strategies Detail Scheduling Process Optimization Recipe Management Performance Management Process Analysis Resource Management Production Execution WIP Material Management Production History Quality Management Some PLCs Machines & Work Centers Production Lines Real-Time Execution Real-Time SPC Real-Time Control Real-Time Monitoring Semiconductor

Pharmaceuticals & Specialty Chemicals ERP Enterprise Performance Reporting Demand Planning Supply Chain Planning Cost Accounting Human Resource Management Sales & Distribution Material Management Production Planning Warehouse Management Maintenance Management numerous mutual assets, expansive formulas, numerous items MES consistence, complex strategies Detail Scheduling Process Optimization Recipe Management Performance Management Process Analysis Resource Management Production Execution WIP Material Management Production History Quality Management SCADA/PCS Equipment Trains Flexible Connections Real-Time Execution Real-Time SPC Real-Time Control Real-Time Monitoring

Oil & Gas and Bulk Chemicals ERP Enterprise Performance Reporting Demand Planning Supply Chain Planning Cost Accounting Human Resource Management Sales & Distribution Material Management Production Planning Warehouse Management Maintenance Management SCADA/PCS Equipment Trains Fixed Connections Large number of control factors, continuous advancement Process Optimization Performance Management Process Analysis Production History Quality Management Real-Time Execution Real-Time SPC Real-Time Control Real-Time Monitoring

MES Functionality Dispatching and Production Resource Allocation Quality Management Data Collection Process Management Production Tracking and Genealogy Document Control Performance Analysis Operational Detail Scheduling

Dispatching Production Manages the stream of generation as employments, requests, bunches, parcels and work arranges by dispatching creation to particular gear and faculty. Incorporates data that is exhibited in the grouping in which the work should be finished.

Resource Allocation & Status Manage the assets specifically connected with control and assembling.

Data Collection & Acquisition Obtains operational generation and parametric information connected with creation gear and procedures. Gives ongoing statuses of creation hardware and procedures.

Quality Management Provides ongoing estimations gathered frame assembling to guarantee appropriate item quality control and to distinguish issues requiring consideration. Incorporates SPC/SQC following and administration of disconnected examination operations .

Process Management Monitors generation and either naturally remedies or gives choice support to administrators to redressing and enhancing in-process capacities. It might incorporate caution administration to handle prepare deviations.

Production Tracking & Genealogy Provides status of creation and demeanor of work. Status data may incorporate faculty, materials utilized, current generation conditions. Incorporates recording of creation data to permit forward and in reverse traceability.

Performance Analysis Provides ongoing reporting of real assembling operations comes about alongside correlations with previous history and expected results. Execution comes about incorporate asset usage, asset accessibility, process duration, conformance to timetable and benchmarks. May incorporate SPC/SQC investigation

Operations & Detailed Scheduling Provides sequencing in light of needs, properties, attributes and creation rules. It is limited and it perceives option and covering operations to ascertain timing of gear stacking

Document Control records and structures that must be kept up with the creation unit. Incorporates work directions, formulas, drawings, standard working systems (SOP), bunch records, move to move correspondence. It sends directions down to operations and gadget controls

Labor Management Provides status of faculty. Incorporates time and participation, confirmation following, and additionally planning function as reason for activity–based costing. May