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MES Solutions
11 March 2014 Invensys proprietary & confidential Slide 1
Why MES? Questions to consider Are you a manufacturer in a regulated industry?
– Food & Beverage
– Tobacco
– Automotive
– Cement
– Pharmaceutical/Chemicals
– Consumer product,…
Do you have “challenges” in your business? – Compliancy issues (21 CFR Part 11, HACCP, BioTerrorism, TREAD)
– Cost of Quality/Product out of balance?
– Supply chain issues?
– Meeting supply/volume targets?
– Managing plant assets/resources?
Do you have legacy/custom software applications to track, trace or document the product manufacturing?
Do you have initiatives like: – LEAN, Six Sigma
– Cost reduction, OEE, DTM
Do you have improvement projects being driven by Operations, Finance, or Quality? Are they X-Departmental?
–
If so, then they may be a good MES candidate
What is MES…
“I need to reduce
downtime”
“I need to have traceability”
“I need to manage recipes”
“I need to improve quality”
“I need to improve yield” “I need to
reduce inventories”
“I need to reduce
cycle times”
“I need to reduce costs”
Integration &
Collaboration
Platform
Enterprise
Integration
Workflow
Open Device
Integration
Web
Portal
Application
Toolkit
Historian
Th
ird
-Part
y O
fferi
ng
s
So
ftware
Ap
plic
atio
ns
Execution
Manufacturing Execution
Systems Batch
Enterprise Asset
Management Mobile Workforce
Management
Performance
Enterprise Manufacturing
Intelligence Performance Measurement
and Reporting Visualization Quality
Asset
Performance
Optimization
Operator Training Design Advanced Process
Control Simulation /
Optimization
Control
DCS PAC SCADA HMI
Safety
Safety Instrumented Systems General Purpose Safety Turbomachinery Control
Measurement &
Instrumentation
Instrumentation Controllers Recorders
Au
tom
atio
n
So
ftware
Ap
plic
atio
ns
Where The Offerings We Will Discuss Fit Within The InFusion Enterprise Control System
11 Functions of MES Fully Covered by Invensys
ISA Model
Level 2
MES
Dispatching
Production
Units
Operations/
Detailed
Scheduling
Resource
Allocation &
Status
Document
Control
Product
Tracking &
Genealogy
Performance
Analysis
Labor
Management
Maintenance
Management
Process
Management
Quality
Management
Data
Collection
Acquisition
Sales &
Service
Management
Enterprise
Resource
Planning
Supply Chain
Management Control
WW
Operations
Software
WW
Performance
Software
WW
Enterprise
Integrator
Avantis
WW QI
Analyst
System
Platform
ArchestrA
Workflow
ISA Model
Level 3
Wonderware MES MESA 11 Point Coverage Operations & Execution Portfolio Solutions “Powered By” MES…
► Track & Trace
► Error Proofing
► “Paper-on-Glass”
► Electronic Batch
Records (EBR)
► Electronic Work
Instructions
► Procedural Execution
► Labor Mgt.
► Receiving & Inspection
► Order Management
► WIP Management
► Inventory Management
► Shipping
► Quality Data Collection
► Weigh & Dispense
► Batch Processing
► Recipe/Spec. Mgt.
► Master Data Mgt.
► HACCP
► …
Em
po
werin
g S
uc
ce
ss
of P
rod
uc
tion
Wo
rkers
D
evic
es
, A
pp
licati
on
s,
En
terp
rise In
teg
rati
on
Database Applications
Asset Management
LIMS Systems
Devices
ERP (SAP, Oracle, Microsoft..)
Manufacturing Operations Management:
Operations Mgt Solution Offerings
Information / Visibility
System Interoperability
Manufacturing Operations Management
Microsoft Technology & Industry Standards
System Platform
Clients
Enterprise Integration
Industry Applications
& Industry Packs
Wonderware HMI, MES & EMI Software Solutions
Operations Performance Quality Batch
Food & Beverage
Intelligence (EMI)
ArchestrA Workflow
Operations & Execution Portfolio MES – Operations Value Proposition
17
Improves Manufacturing Agility by providing real-time production execution information and alerts to the right people, at the right time
Drives Consistent Production Execution through strict enforcement of electronic manufacturing procedures (process, operator, equipment & materials) associated with semi-finished and finished goods – enforces “best practices”
Captures Comprehensive Manufacturing Genealogy by collecting a complete production routing history (including assets), labor history and material usage history – improves compliance and governance
Improves Decision Support & Planning within the Supply Chain by providing real-time order, material (raw material & WIP), equipment and labor status
Operations & Execution Portfolio MES – Operations Features
Product Definition
Ability to Define Raw, Semi-Finished or Finished Goods Attach Multiple BOM Definitions (versions) to a Product Attach Multiple Specifications (versions) to a Product Synchronize Products Definitions with External Systems
Bill of Material Definition
Multi-level BOM (n-tier) Define Multiple Substitutes per BOM Item Define Co-Products / By-Products Configure Specific Material Processing and Tracking
Business Rules per BOM Item (e.g. backflush, maintain inventory, must consume from previous step, etc.)
MES 4.0 Operations
Mobility
Product Definition
Operations & Execution Portfolio MES – Operations Features (cont.)
Production Management & WIP Execution
Full Production/Process Order Management Define and Execute Product Specific Production Routings Record and Track Production, Consumption and Labor WIP Status and Characteristics
Inventory Management
Configure Business Rules for Tracking Inventory on the Plant Floor (e.g. maintain composite lots, etc.)
Can track bulk, lot or serialized inventory items Ability to Transfer, Split, Combine, Receive, Ship and
Reclassify Inventory Items
MES 4.0 Operations
Mobility
Production Execution
Storage Management
Ability to Define Fixed or Mobile Inventory Locations Ability to Monitor the State of Inventory Locations Track the Movements and Location of Mobile Storage
Devices
Operations & Execution Portfolio MES – Operations Features (cont.)
Equipment / Machine Setup
Common Equipment Setup Templates Enable Consistency in Equipment setup Ability to Capture a “Golden” Setup Ability to Enforce Steps and/or Procedures
Procedure Step Manager
Guide an Operator Through a Manual or Semi-Automatic Procedure at a Particular Manufacturing Operation
Configure Required “Step Actions” (e.g. consume material, acknowledge message, view document, etc.)
MES 4.0 Operations
Mobility
Equipment Operations
Production Event Tracking
Ability to Capture Production Events Including Counts, Weights, Scrap and Reason codes
Ability to Report and Drill Through History, Enabling Genealogy, Traceability
Operations & Execution Portfolio MES – Operations Features (cont.)
Enable Plant Document & Work Instruction Definition
Define Electronic Folders with Associated Documents and Work Instructions (multiple versions)
Configure Document Viewers to Use for Specific Document Types
Manage Links to Other Documents
x x Work Instructions & Document Management
View Many Different Document Types (e.g. PDF, MS Documents, Web Page, etc.)
Link Work Instructions and Documents to Products, Production Orders, Operations, Work Centers or Procedural Steps
MES 4.0 Operations
Mobility
Work Instructions
Operations & Execution Portfolio MES – Performance Value Proposition
22
Reduce Capital Expenditures by identifying the most productive assets for continued operation
Improve Asset Utilization by identifying production bottlenecks more quickly and increasing supplier accountability
Increase the Capacity of your existing assets by pinpointing the causes of unplanned downtime and improving operational efficiency
Leverage Best Practices by comparing line-to-line and plant-to-plant performance, including real-time OEE measures
Empower Operators by providing visibility to real-time asset performance KPIs that enable them to “take action”
Operations & Execution Portfolio MES – Performance Features
Equipment Utilization
Ability to Detect and Capture Utilization Events Ability View Equipment Events Ability to Monitor and Record Equipment State Ability Automatically or Manually Assign Reason Codes
Equipment Performance
Ability to Calculate OEE for Equipment / Line Ability to Trigger Events and Display Ability to Analyze Event Frequency and Duration Ability to Assign What States Affect OEE Calculation
Production Progress
Provide a Clear Indication of Job or Production Order Progress to the Operator in Real Time
Ability to Calculate OEE Other Key Parameters Ability to Estimate Expected Completion Date and Time
Mobility
MES 4.0 Performance
Batch
Wonderware Operations Software
Simple batch management with recipe
definitions using site specific processes
Accurate equipment setup with automatic
download of set points
Wonderware InBatch
Powerful batch execution engine with
dynamic allocation of shared equipment for
even the most complex batch processes
Graphical recipe definitions according to
S88 with unit procedures, operations and
phases for equipment independent master
recipes
Accurate Management of Batch Processes
Quality
Wonderware QI Analyst
Real-time and historical SPC with
comprehensive charts and custom run
rules with alarm generation upon violations
Minimize costly scrap and rework through
detection of process variations and better
understanding of actual process
capabilities
Wonderware Operations Software
Central administration of process and
product specifications with versions and
min/max limits per BOM entity
Reduce Variances with Specification and SPC Management
Avantis.PRO
•Enterprise Asset Management
•Maintenance
•MRO Inventory
•Procurement
•Integration Toolkit
Avantis.DSS
•Maintenance & Reliability Decision Support
•KPI Portal
Avantis Approvals
•Document Approvals workflow
Avantis Asset Intelligence
•Asset Health Aggregation and Visualization
Avantis Condition Management
•CbM Extensions
•Multi-variable Rules
Avantis Continuous Monitoring
•Voltage & Current Analysis
•Stress Wave Analysis
Asset Mgt with
Slide 26
Avantis Asset Performance
Avantis EAM Suite
Wonderware EMI Strategy Enterprise Manufacturing Intelligence
Production/Process Information Platform
Self-service access
to information
& content authoring
Share content
& Collaborate
User-friendly
Configuration &
Administration
Wonderware &
Non-Wonderware
Data sources
Incremental approach
Wonderware Intelligence (EMI)
• Multiple databases and/or multi-site deployment
• Easy configuration of Information Model contextualizing multiple data sources
• Self-Service browsing of information model, analytics and dashboard creation
• Integrate content previously created
Site
Multi-site Information Browser Dashboards Analytics
Wonderware Intelligence: Problems Solved
Disparate
Data Sources
Diverse
Data Sources
Naming scheme
inconsistency
Data overload
Inconsistent
Metrics
Broad Data
Connectivity
Domain specific tools,
Applications and Templates
Master data referencing
and data cleansing
Self-service dashboards,
reports and analytics
Data contextualization Data caching
and storage
Data Aggregation
and Alerts Pre-Aggregated Data
Central and Customizable
Metric Definition
Business-friendly Model
Access Layer
Intelligence
Slow Data
Access
Production
Systems Impact
Dependence on
IT Department
Complex
Data Access
Long solution
Development
User Problems User Problems
What is ArchestrA Workflow Software?
30
Manufacturing Business Process Mgt. (BPM) Framework for the Invensys Operations
Management Portfolio
Visualize/collaborate/improve operations
ArchestrA Workflow for Quality-Example
Assigned back
to Greg
(ALERT)
System Updates
the Company
SharePoint KB
No
Action/Notification/Event
Alert
Successful Completion
Legend
Jay (Supervisor in charge)
Greg (Quality Manager)
John (Quality Inspector,
part of Greg’s team)
Start
Jay
Jay Receives a
Complaint Call Jay Runs the Batch
Genealogy Report
Material with Issue
is Identified
John is notified to
continue investigation John
John fills out “Hold Lot Investigation
form” and submits for approval
Jay submits Hold
Lots Form
Inventory system notified
To put specific Lots on Hold!
Workflow is
triggered
Yes
Workflow Ends
Has Greg
Approved the
Audit Report?
System Notifies Greg
for Approval
Notification
sent to Greg Greg
Greg reviews
Batch Report
ArchestrA Workflow Software How Do We Package It?
ArchestrA Workflow – Standard or Enterprise Edition
ArchestrA Workflow – “Add-On’s”
User Directory
System Platform EMI MES Mobile Batch ROMeo
Platform & Application Integration Connectors
Microsoft Integration Other Integration
Microsoft Integration Forms Designer
DB Integration
Enterprise Integration
Plant Manager
Global Distributed Manufacturing
Is The New „Norm‟
MANUFACTURING
PLANT MANUFACTURING
PLANT
MANUFACTURING
PLANT
NEW CUSTOMER
CUSTOMER
SPOT MARKET
CUSTOMER
Field Sales
Customer Service
Plant Manager Product Variability -
Inconsistent quality: by
plant, by product, by shift
Difficulty meeting tighter
customer specifications – Can’t match quality to
orders
No visibility – Can’t see
plant wide production status
due to 10 - 200 disparate
shop floor info systems
Varying process
conditions lead to Higher
energy use
Lack of predictability
Can’t see business performance
to plan, and recommend new
plans to affect results
Capacity erosion –
high off-grade produced
and wide quality swings
Plant Manager
Production Processes
Shared Information
Orders Shipped
Missed orders
Orders
returned
Orders
changed
VP Sales
VP Manuf.
VP BU
Planners
CIO
Inflexible production
process contributes to Missed Opportunity
Hidden capacity
obscured by inefficient
grade transitions &
conservative operation
Enterprise
Integration
Wonderware Enterprise Integrator
Transactional integration with ArchestrA
real-time data model
Reduced Cost of Ownership using industry
standards ISA-95 and B2MML
Wonderware Supply Chain Connector
Out-of-the-box integration using pre-
defined mappings.
Simple, yet powerful integration capabilities
in a standardized formats
Tight Alignment with Business Processes
Ecosystem
35
• More than 3,000 partners
• Complementary hardware, software
• Systems Integration & Consulting
• Suppliers, distributors, OEMs
• Complete solutions providers
• Global/regional coverage
► Raised OEE by 3% in first year
► $200,000 ROI on an initial investment of $80,000
► Payback in 5 months
Direct bottom line results…
A Customer Success Story
Major Beverage Container Manufacturer • Leading producer of plastic beverage containers • Products in such demand they can sell more than they can produce
Success Story 2
► Within 3 months, identified problem areas in bottleneck machines
► Due to increased efficiency, able to cancel large capital expenditure (> $1.5 Million)
Direct bottom line results…
Major Paper Producer • One of world’s largest producers of paper products • $22 billion annual revenue • Legacy system relied on manual entry of downtime fault reasons • Planned large capital expenditure to eliminate production bottleneck • Implemented Wonderware software as interim measure
11
Mar
ch
201
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Invensys proprietary &
confidential