Achieving Operations Excellence through MES Best Practices

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Achieving Operations Excellence through MES Best
Practices

• 15 May 2007

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Agenda

• Definition

Processes
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Best Practice vs Leading Practice
Achieving Operations Excellence through MES Best
Practices
Contradictive!

• there can be no better perfection

• If we are perfect then there is no need to
  strive for Excellence
• Prefer using the term Leading practice instead
  of Best practice

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Definition

• Defining the manufacturing enterprise

• Defining MES

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What do you see?
A Young or Old Lady ?
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What do you see?
Two heads or a Vase?
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What do you see?
A Duck or a Rabbit?
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What do you see?
Perception

• everyone has different perceptions

• perception is the way we interpret information
  presented to us

• factors such as experience, expectations and
  physical, emotional
• psychological influences affect what we perceive

• the same applies to MES

• MES is prone to varied interpretations

• MES must be defined clearly amongst all
  stakeholders

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Defining the Manufacturing Enterprise
Business Intelligence
The PURDUE View
Business Planning/ERP
Manufacturing Execution Systems
GAP
Operational
Tactical Strategic
Automation Control
Actuators
Continuous
Discrete
Batch
Instrumentation
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Defining the Manufacturing Enterprise
Business Planning/ ERP
Process Optimisation
MES
Inbound
Outbound
Process Design
Plant Floor
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Defining MES

• those activities of a manufacturing facility that
  coordinate personnel, equipment, material, and
  energy in the conversion of raw materials and/or
  by-products into products. It includes activities
  that may be performed by human effort and
  information systems. By performing these
  activities, the manufacturing facility can
  achieve its stated business objectives

• Consists of 4 main categories

Maintenance Operations
Production Operations
Inventory Operations
Quality Operations

• Based on the ISA-95 Standard

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Defining MES
Production Operations Management
Maintenance Operations Management
Quality Operations Management
Inventory Operations Management
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Some pointers when defining MES

• MES is an evolving area and it is therefore
  imperative that it is clearly defined
• Speak the same language

• When defining MES try as best as possible to
  involve key stakeholders
• Control Automation team
• Business Planning / ERP

• May lead to functional or territorial battles!

• If the groups are large try to form smaller core
  teams but make sure effective communication is
  given to all stakeholders

• Communication can be the make or break to an MES
  initiative

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Processes

• Brief introduction to processes

• Benefits

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Processes

• It is a workflow (logical sequence) of activities
  that is aimed at achieving a particular goal or
  objective

Value Chain
Level 0
Macro Process
Level 1
Process
Level 2
Activities
Tasks
Level 3
Procedures
Level 4
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Processes a hypothetical example
Production
Research development
Sourcing
Sales
Distribute
Level 0
Prospect for Clients
Complete quote
Check Stock Levels
Place Order
Level 1
Fill in order form
Capture on system
Confirm delivery date
Print Order
Level 2
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Benefits

• Processes consider other very important aspects
  other that just a logical sequence of activities
• Inputs
• Outputs
• Description of activities
• Roles Responsibilities of each activity
  (people)
• Performance measures targets

• Clearly described process provides an insight to
  what is or can being done by the enterprise

• Enables better knowledge management

• Enables optimisation

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• Glue that binds Strategy, People, Technology

• Enables Collaboration Integrations through
  links to other processes

• Enables governance

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Manufacturing Business Processes

• Models of Manufacturing Operations Management
  ISA-95 part 3
• There is a generic set of activities that are
  applied to the 4 Manufacturing Operations
  Management categories
• The generic set of activities are logically
  combined to form a process model
• The Model defines a general Request-Response
  Cycle Supporting Activities

Maintenance Operations
Quality Operations
Production Operations
Inventory Operations
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Summary
Maintenance Operations
Production Operations
Inventory Operations
Quality Operations
Six Sigma
Lean Manufacturing
JIT
Governance
Collaboration Integration
Strategy
People
Technology
Knowledge Management
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INDUSTRY PROVEN BENEFITS OF MES

• Informed Decision Support
• Improved IT Automation ROI
• Enforce Regulatory Conformance
• Productive, Empowered Employees
• Improved Product Quality
• Improved Customer Service
• Lower Operating Costs
• Improved operations

Article Industry Directions - 2004 The MES
performance advantage Best of the Best Plants
use MES
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Questions Discussions