HF-7761EN_C (2013-01)

Manufacturing Execution System

Dr. Naveen Gautam Managing Director

Manufacturing Execution System

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Agenda

Overview – Scope of MES

Business Drivers

MES Offerings

MES – Implementation at Hella

Outlook and Summary

Manufacturing Execution System

MES - Overview

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System for integration of production / QM and Logistic

MES is the synthesis of all SW applications that are necessary for planning, controlling and

regulation of production processes and interfaces between ERP system and the shop floor

MES systems are capable of providing monitoring and supervisory control functions like production management, company and machine data acquisition, quality data acquisition resulting in traceability in real-time.

ERP

MES

Shop floor

Enterprise Level

Actual registration of

production processes

Process & Workflow

Manufacturing Execution System

MES - Scope

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ERP/MRP

˗ Forecasting ˗ Costing / Financials ˗ Production ˗ Planning ˗ SOPs ˗ Human Resources ˗ Inventory ˗ Distribution

Planning

MES ˗ Detail Scheduling ˗ Schedule Execution ˗ WIP & Resource Tracking ˗ Traceability and interlocking ˗ Document Control ˗ Data Collection ˗ Resource Management ˗ Quality Management ˗ Yield Analysis ˗ Process Management ˗ Maintenance Mgmt. ˗ Change Management

Execution

Process Control

- Operations - Sequencing - Work Instructions - Labor Instructions - Safety - Maintenance - PLC control - Process Sensors - ASRS - Test Stations

Control

Customer Focus: Business Decisions

Product and Process Focus: Plantwide Mfg. Decisions

WorkStation Focus: Prod. Line/ Process Decisions

- Production Demand - Master Schedules - BOM/ Formulations - Inventory - SOPs

- Process & Work Instructions - Operator Instructions

- Order Status - Resource Usage - As – Built Genealogy - Yields

- Workstation status - Process status

Manufacturing Execution System

MES – Business Drivers

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• Real time data transparency:

Operational Excellence

• Real time quality check: Zero ppm

• Reduction Non Quality Expenses (NQE)

• Reduction Time to Market (TTM)

• Total Cost of Ownership (TCO)

• High Traceability: Contained Warranty

• Effective Change Mgt.

Competitive

Advantage

Localization More Launches New Safety and OE Req Offering

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Manufacturing Execution System

MES - Offerings

System for integration of production / QM and Logistic

Incoming goods / storage /

Barcode / DB

SMT, Assembly ->Process

and Production parameter

Register rework

Assembly tests / ICT / EOL

Vision

Storage / Outgoing goods

Interlocking

• Traceability for risk reduction

• Interlocking tool : real time inspection and blocking

• Consistent documentation for product and process

• Transparent and real time visibility of data

• Quality tool

• According to the OE and legal

requirements...

Advantage in competition

MES - Implementation at Hella

Architectural Overview

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Shopfloor

Interfaces

Application = iTAC

Network

Redundant application servers

Incoming goods

Goods inward department books components to SAP with “SIGN“ traceability. This mark is syncronistic send to iTAC. SAP

ERP PDM BOM

Reports, OEE…

Oracle DB

Redundant database Cluster

API-DLL File, OPC, Fileinterface , Gateway PC, Database interface

ERP

Stru

ctu

re

time relevant

Status iTAC and Hella - Integrated architecture

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Label- Printer / Laser

- SMT ICT AOI

Repair

Reflow Oven

Packaging / Logistic box

EOL Manual Assembly

Transport

iTAC MES.Suite with Fail over, Load Balancing, 24/7

Traceability and interlocking is

possible in the entire production Incoming

goods

Generate UID

Label for

components

Scanning of component rolls and PCB

Saving Serial number Result Ok at ICT deposit

in EEProm and DB

EOL identify internal serial number. Critical measure values from tester, E2PROM-

Parameters and date/ time of the EOL are saved with the serial number of the device at central DB

SAP input

traceability

MES - Implementation at Hella

Overview trace flow

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MES - Implementation at Hella

MES – Traceability and Interlocking

Supplier •Create Traceability information

•Marking of packaging box

Incoming goods • Registration of Traceability informationen to the Hella System

• Create an Unique ID

Production

• Serial number depend production

• Verification/Interlocking of Trace before production

• Combination Hella Unique ID to Serialnumber Product

• Combination of delivery note and produced SNR

OEM •Combination Serial number of product with

Car serial number

Logistic flo

w Trace

ability

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MES - Implementation at Hella

Hella MES Status

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MES - Implementation at Hella

Hella MES Status

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MES - Implementation at Hella

Hella MES Status

Example Dashboard framework Boundary to ERP Integration

Machine

conditions

Performance

Errors

Andon

Monitor

Station

Evaluation

Line

Evaluation

iTAC Dashboard

Real time live data

iTAC

ERP Interface

Key Performance Indicator

Framework

Utilization

rate

PPM

OEE

Performance

rate

Counted

parts OEE

Trends

Failure

relation

Downtimes

Real time live data History / archive data

MES - Implementation at Hella

Outlook and summary

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Standard MES system will replace distributed individual solutions

MES system will offer the backbone for the „Digital Factory“

MES system will further support to be global competitive

Avoidance and minimization of equipment downtimes

Complete tracability and interlocking

Increased production control and granular production planning

Improvement of existing processes and procedure models

Bi directional communincation with ERP

Outlook

F-7761DE_C (2011-06)

Thank you