Manufacturing execution systems optimal design, planning, and deployment

Contents......Page 8
Foreword......Page 16
Acronyms......Page 18
1.1 Motivation......Page 24
1.2 Aim of This Book......Page 25
1.3 Structure of This Book......Page 26
2.1.1 Development of Business Data Processing......Page 28
2.1.2 The Integration Concept: From CIM to the Digital Factory......Page 29
2.2.2 Company Management Level......Page 31
2.2.3 Production Management Level......Page 33
2.3.1 Patchwork......Page 36
2.3.3 Excessive Response Times......Page 37
2.3.4 High Operating and Management Outlay......Page 38
2.4.1 Target Management......Page 39
2.4.2 Integration of Applications and Data......Page 41
2.4.3 Real-Time Data Management......Page 44
2.4.4 Information Management......Page 47
2.4.5 Compliance Management......Page 48
2.4.6 Lean Sigma and MES......Page 50
2.5 Summary......Page 53
3.2.1 ISA......Page 54
3.2.2 IEC......Page 58
3.2.4 FDA......Page 59
3.2.5 NAMUR......Page 60
3.3.1 MESA......Page 61
3.3.2 VDA......Page 62
3.3.4 ZVEI......Page 63
3.4.2 ERP/PPS Systems......Page 64
3.4.3 Process Management Systems......Page 65
3.4.5 Simulation Systems......Page 68
3.5.1 Historical Development......Page 69
3.5.2 Product Model......Page 70
3.5.4 Implementation Strategies......Page 71
3.5.5 Points of Contact with MES......Page 72
3.6 Summary......Page 73
4.1.1 Classification in the Overall System......Page 76
4.1.2 General and Complete Data Model......Page 77
4.1.3 Origins of Master Data......Page 79
4.2.1 Relevant Concepts......Page 80
4.2.2 The Operation......Page 82
4.2.3 The Work Plan......Page 86
4.3.1 Description of Production Environment......Page 89
4.3.2 Production Personnel......Page 94
4.3.3 Operating Resources......Page 95
4.3.4 Materials and Preliminary Products......Page 96
4.3.5 Information and Documents......Page 97
4.4 System and Auxiliary Data......Page 100
4.5.2 Production Data, Operating Data, and Machine Data......Page 102
4.6 Summary......Page 104
5.2 Order Data Management......Page 106
5.3.1 Demand Planning......Page 108
5.3.3 Material Disposition in the MES or ERP System......Page 109
5.3.5 Interaction between the ERP System and the MES......Page 110
5.4.1 Planning Objectives......Page 111
5.4.3 Work Scheduling......Page 112
5.4.4 Strategies for Sequence Planning and Planning Algorithms......Page 114
5.4.5 Forward Planning/Reverse Planning/Bottleneck Planning......Page 115
5.4.6 Collision-Free Planning of a Time Container......Page 116
5.5.1 Core Elements......Page 117
5.5.2 User Interface......Page 118
5.6 Personnel Planning and Release of Orders......Page 119
5.7 Summary......Page 120
6.1.2 Functions of Order Fulfillment......Page 122
6.1.3 The MES Terminal......Page 123
6.2.1 Changing Tools......Page 126
6.2.2 Machine Settings......Page 127
6.2.4 Test Run......Page 128
6.3.4 Material Flow Control......Page 129
6.3.5 Order Processing and Operating Data Recording......Page 132
6.3.6 Process and Quality Assurance......Page 133
6.4.1 Involved Departments......Page 135
6.4.3 Ongoing Analysis and Evaluations......Page 139
6.4.4 More Long-Term Analyses and Evaluations......Page 140
6.5.2 Preventive Maintenance and Repair......Page 141
6.6 Summary......Page 142
7.1.1 Fundamental Variants......Page 144
7.1.2 Overview of Central Components......Page 145
7.1.3 Platform Independence......Page 147
7.1.4 Scalability......Page 148
7.1.5 Flexible Adjustment versus Suitability for Updates......Page 150
7.1.6 MES and Service-Oriented Architecture (SOA)......Page 152
7.2.2 Resource Monitoring......Page 153
7.2.3 Scaling the Database System......Page 155
7.2.4 Data Management and Archiving......Page 156
7.3.2 Interface with Production......Page 157
7.3.3 Interface with an ERP System......Page 163
7.3.4 Interface with the IT Infrastructure......Page 166
7.4.1 Usage and Visualization......Page 167
7.4.2 Reporting......Page 171
7.4.3 Automated Information Distribution......Page 173
7.5 Summary......Page 174
8.1.1 Calculation of Cost-Effectiveness......Page 176
8.1.3 Value-Benefit Analysis......Page 177
8.1.5 Total Cost of Ownership......Page 178
8.2.1 Assessing Cost-Effectiveness in Practice......Page 179
8.2.2 Rationalization Measures in Production......Page 180
8.2.3 MES for Reducing Sources of Loss......Page 183
8.3.1 Integrated Data Transparency......Page 184
8.3.2 Reducing Time Usage......Page 185
8.3.3 Reducing Administration Expenses......Page 188
8.3.5 Improved Quality......Page 189
8.3.7 Increasing Employee Productivity......Page 190
8.4 The Costs of an MES......Page 191
8.5 Summary......Page 192
9.1.1 Selection of Components......Page 194
9.1.2 Implementation Strategies......Page 196
9.1.3 Problems during Implementation......Page 197
9.2.1 Establishing the Core Team......Page 199
9.2.3 Establishing the Project Team......Page 200
9.3.1 Introduction......Page 201
9.3.2 Existing Infrastructure......Page 202
9.3.3 Existing Processes and Required Functions......Page 203
9.3.4 Key Figures as the Basis for Monitoring Success......Page 204
9.3.5 Suitable Key Figures for Success Monitoring......Page 205
9.3.6 Other Factors for Success......Page 207
9.4 Creation of a Project Plan......Page 208
9.5 Contract Specifications......Page 209
9.6.2 Short-Listing and Limiting to Two or Three Applicants......Page 210
9.6.3 Detailed Analysis of the Favorites and Decision......Page 212
9.7.1 Project Management......Page 214
9.7.2 Training Management......Page 215
9.7.3 Operating Concept......Page 216
9.8 Summary......Page 218
10.1 Mixed Processes......Page 220
10.2.2 Description of the Production Process......Page 221
10.2.5 Challenges for the MES......Page 223
10.3.2 Description of the Production Process......Page 227
10.3.3 Basic Quantity Units and Production Units......Page 232
10.3.5 Tasks of the MES......Page 233
10.3.6 Challenges......Page 235
10.3.7 Realization and Implementation......Page 236
10.4 Summary......Page 237
11.1 Merging the Systems......Page 238
11.2.2 Request Handling......Page 240
11.2.3 Concept Documentation and Designing Requirements......Page 241
11.2.4 Construction of the Product......Page 242
11.2.5 Computer-Aided Flow Planning......Page 243
11.4 Merging Consultancy Activities and IT Systems......Page 244
11.5 Summary......Page 245
12 Summary of the Book......Page 246
References......Page 250
A......Page 252
B......Page 253
C......Page 254
D......Page 255
E......Page 256
H......Page 257
J......Page 258
M......Page 259
N......Page 260
P......Page 261
R......Page 263
S......Page 264
T......Page 265
X......Page 266
D......Page 268
M......Page 269
R......Page 270
Z......Page 271