Manufacturing Execution Systems (MES) Industry specific Requirements and Solutions ZVEI - German Electrical and Electronic Manufactures‘ Association Automation Division Lyoner Strasse 9 60528 Frankfurt am Main Germany Phone: + 49 (0)69 6302-292 Fax: + 49 (0)69 6302-319 E-mail: [email protected] www.zvei.org ISBN: 978-3-939265-23-8 CONTENTS Introduction and objectives IIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIII5 1. Market requirements and reasons for using MES IIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIII6 2. MES and normative standards (VDI 5600 / IEC 62264) IIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIII8 3. Classification of the process model according to IEC 62264 IIIIIIIIIIIIIIIIIIIIIIIIII 12 3.1 Resource Management IIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIII13 3.2 Definition Management IIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIII14 3.3 Detailed Scheduling IIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIII14 3.4 Dispatching IIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIII15 3.5 Execution Management IIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIII15 3.6 Data Collection IIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIII16 IMPRINT 3.7 Tracking IIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIII16 3.8 Analysis IIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIII17 Manufacturing Execution Systems (MES) 4. Typical MES modules and related terms IIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIII18 Industry specific Requirements and Solutions 4.1 Overview IIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIII18 4.2 Short description of typical MES modules and MES-related terms IIIIIIIIIIIIIIIIIIIIII20 Publisher: ZVEI - Zentralverband Elektrotechnik- und Elektronikindustrie e.V. 5. Deployment, purpose, and environment of MES modules based on (German Electrical and Electronic Manufactures‘ Association) typical application examples IIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIII 26 Automation Division 5.1 Production of active pharmaceutical ingredients IIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIII26 5.2 Food and beverages - brewing industry IIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIII30 Contact: 5.3 Refineries and petrochemical industry IIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIII36 Carolin Theobald 5.4 Chemicals / specialty chemicals IIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIII40 Lyoner Strasse 9 60528 Frankfurt am Main 5.5 Serial production (automotive industry and suppliers) IIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIII48 Germany 5.6 Machine / plant construction (made-to-order construction) IIIIIIIIIIIIIIIIIIIIIIIIIIII54 Phone: +49 (0)69 6302-429 5.7 Paper / Metal IIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIII58 Fax: +49 (0)69 6302-319 E-mail: [email protected] 6. Essential similarities and differences between MES applications in the process www.zvei.org and manufacturing industries IIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIII 62 6.1 Similarities IIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIII62 Design: 6.2 Differences IIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIII64 NEEDCOM GmbH www.needcom.de 7. Practical advice for approaching MES projects IIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIII 65 8. Added value and benefits IIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIII 70 Printing: Berthold Druck GmbH 8.1 Biopharma case study: comprehensive plant automation – ERP-MES-DCS IIIIIIIIIIIIIII72 www.berthold-gmbh.de 8.2 Food and beverage case study: energy data acquisition as decision support for investments IIIIIIIIIIIIIIIIIIIIIIIIIII73 ISBN: 978-3-939265-23-8 8.3 Refinery case study: long term planning and scheduling IIIIIIIIIIIIIIIIIIIIIIIIIIIIIII74 8.4 Automotive industry case study: order management for powertrain assembly IIIIIIIIIII76 Frankfurt, July 2011 8.5 Single-part manufacturing case study: MES from engineering to transportation logistics 78 8.6 Paper industry case study: production efficiency improvements IIIIIIIIIIIIIIIIIIIIIIII81 © ZVEI - Zentralverband Elektrotechnik- und Elektronikindustrie e. V. 9. Summary and outlook IIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIII 83 Despite careful control, ZVEI does not assume any liability for the content. Literature IIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIII 85 List of Figures IIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIII 85 List of Tables IIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIII 86 INTRODUCTION AND OBJECTIVES Introduction and objectives This brochure was created by the ZVEI Working Group „Manufacturing Execution Systems“, in the Numerous company or industry-specific software solutions and products have been developed to manage Automation Division, assisted by the following: administration and organization of manufacturing processes. Although they are generally presented as MES (Manufacturing Execution System), the scope of these solutions ranges from „My Excel Sheet” to comprehensive management, organization, and automated processing of all production-related processes. Dr. Marcus Adams [email protected] This brochure is not another attempt to define the term Manufacturing Execution System. Rather, in issuing this brochure, the objective of the ZVEI Working Group „MES” is to provide the interested reader and the professional audience with an overview of currently existing or feasible solutions which fulfill differing industry-specific requirements. The objective of this brochure is to promote the utiliza- Dr. Thomas Bangemann [email protected] tion of suitable MES applications for optimized production. The working group has used the „Enterprise-Control Systems Integration – IEC 62264” set of standards as a basis for product and vendor independent presentation of the functionality. Chapters 1 through 3 Herbert Fittler [email protected] provide a short introduction to this standard which is also known as S95. Currently, different terminol- ogy for the same MES terms and tasks is used across industries and even among vendors. Therefore, Chapter 4 classifies the most important terms based on the S95 structure and terminology, providing Christian Friedl [email protected] guidance through the multitude of different terms and products. Based on industry-typical requirements, chapter 5 presents the opportunities and benefits of MES func- tions. Chapter 6 explains the essential similarities and differences of MES applications in the process Dr. Iiro Harjunkoski [email protected] and manufacturing industry. Chapters 7 and 8 provide an outline of the requirement definition and the selection of MES functions, and present their benefits based on specific examples. Chapter 9 summa- rizes this brochure and presents an outlook on future MES solutions. Gottfried Hochfellner [email protected] As presented in chapter 5, already today, comprehensive industry-specific solutions are available, which address the respective requirements by their scalability, modularity, and integration capability. These solutions can contribute significantly to improving the operational excellence of an enterprise. Erdal Kara [email protected] The industrial operators are challenged to maximize this opportunity. Dr. Jürgen Löffler [email protected] Andreas Meyer-Weidlich [email protected] Carolin Theobald [email protected] Max Weinmann [email protected] Dr. Markus Winzenick [email protected] Prof. Martin Wollschlaeger [email protected] Martin Zeller [email protected] 4 5 1 MARKET REQUIREMENTS AND REASONS FOR USING MES 1 MARKET REQUIREMENTS AND REASONS FOR USING MES 1 Market requirements and reasons for using MES The real-time capability of MES spans multiple interdisciplinary requirements (such as order planning and control, material management, PDA, MDC, quality management, and document management) and provides a direct connection with the production process. Furthermore, integration of the extended supply chain and global procurement as well as the regional In order to evaluate the state of the art and the development of MES solutions, the place of MES in the corporate sales presence in developing markets is required. history of automation must be considered. Today’s MES solutions include former CIM components such as CAP (Computer Aided Planning), CAM (Computer Aided Manufacturing), CAQ (Computer Aided MES is not only the operational link between „production” and „enterprise” but also links all partners Quality Assurance), PDA (Production Data Acquisition), MDA (Machine Data Acquisition), and PTR / T&A within the supply chain. This enables a continuous, holistic, and manageable value stream. (Personnel Time Recording, Time & Attendance). On this basis, MES is emerging as a strategic element for flexible and integrated production. A MES However, these CIM components were not thoroughly integrated into the corporate processes. Instead, combines all tasks of modern production management in a comprehensive software system for today. they were mostly used as single purpose applications on department level. Due to increasing corporate At the same time, this system is the operational platform for any enterprise evolving towards the „digi- CAP integration as well as better understanding of internal and external