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Wonderware Operations Software “Improving Manufacturing Operations” Terence Tan General Manager

Wonderware Operations Software “Improving Manufacturing Operations” Terence Tan General Manager. MES. Definition according to MESA International:. Definition according to ISA:. What is MES?.

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Wonderware Operations Software “Improving Manufacturing Operations” Terence Tan General Manager

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  1. Wonderware Operations Software “Improving Manufacturing Operations” Terence Tan General Manager

  2. MES Definition according to MESA International: Definition according to ISA: What is MES? The MES layer focus in a group of activities (operations, inventory, quality and maintenance activities) corresponding to Level 3 in the Functional Hierarchy model. Manufacturing Execution Systems (MES) deliver information that enables the optimization of production activities from order launch to finished goods. MES anufacturing xecution ystem

  3. ISA Model Level 4 Business Planning & Logistics Plant Production Scheduling, Operational Management, etc Level 3 Manufacturing Operations & Control Dispatching Production, Detailed Production Scheduling, Reliability Assurance, ... Levels 2,1,0 Batch Control Continuous Control Discrete Control

  4. Purdue CIM Model Level 4: Enterprise Resource Planning System Level 3: Manufacturing Execution System Level 2: Process Supervisory System(s) Level 1: Real time Controllers Level 0: Instruments and Actuators

  5. The MESA model Sales & Service Management Enterprise Resource Planning Operations/ Detailed Scheduling MES Resource Allocation & Status Document Control Dispatching Production Units Product Tracking & Genealogy Performance Analysis Labor Management Maintenance Management Process Management Quality Management Data Collection Acquisition Supply Chain Management Control

  6. What is Wonderware MES? Wonderware MES Wonderware MES is an out-of-the box, configurable, modular Manufacturing Execution System (MES) software focused on production execution, shop floor data collection and analysis.

  7. Product History Wonderware Operations and Performance 3.5 March 2009 Wonderware Operations and Performance 3.4 February 2008 EPM 2.0 = Factelligence 3.1 + QuickStart October 2007 WonderwareFactelligence 3.1 July 2007 First version of Factelligence by CIMNET 2002

  8. Wonderware MES Features Wonderware MES will enable you to… Deliver planned vs. actual production • Electronic Work Order Management • Recording of Production Events using Improve process and production consistency • Centralized Manufacturing Model • Production Rules • Certifications using Improve inventory velocity • Real time inventory management • Detailed definition of materials, substitutes and byproducts • Bill of Materials using Reduce order lead time • Dynamic prioritization and sequencing • Labor management • Connection to HMI/SCADA using Monitor and analyze production performance • Downtime • Utilization • OEE using

  9. Licensing Wonderware MES Utilization and Downtime OEE Performance Work Order Execution Bill of Materials Production Events Tracking Parameters Download Operations Standard Operations Premium Data Collection Inventory Certifications Labor Management Steps

  10. Wonderware MES Architecture Clients Manager Configurator Supervisor Operator Custom .NET App IIS Middleware Wonderware MES Service COM+ Package Factory Connector Database Server Production DB

  11. Wonderware MES Middleware

  12. Wonderware MES Client

  13. System Requirement - Software

  14. System Requirements - Hardware

  15. Operations Software…Functional Overview • Quick Changeovers Between Products and Lines • Electronic work orders, BOM, specs • Delivering Planned vs. Actual Production • Work orders, data collection, symbols • Process and Production Consistency • Templates, BOM, specs, security • Quick Changeovers Between Products and Lines • Electronic work orders, BOM, specs • Delivering Planned vs. Actual Production • Work orders, data collection, symbols • Process and Production Consistency • Templates, BOM, specs, security Operations Premium Operations Standard Work Order Execution Specifications Bill of Materials • Improve Inventory Turns and Reduce Inventory Cost • Accurate recordkeeping, visibility • Reduce Order Lead Time • Dynamic allocation of production assets • Enforcement of production rules / steps • Reduced Time-to-volume for New Products • Map entity model, product / process context • Improved Compliance & Governance • Electronic system records, history Parameters Download Data Collection Inventory Certifications Labor Management Steps Operations Software – Standard Edition

  16. Improve Productivity via faster product or line ‘Changeovers’ • Central administration of process and product parameters • Maintain Bills of Material (w/ version mgt) • Product & material specs w/ min/max limits per BOM entity • General recipe definitions using site specific processes • Accurate equipment setup • Site specific product specifications • Automatic download of set points • User-based parameter management • Operator visibility of set point values (.NET Controls) • Associate drawing, multimedia file or documents to specifications • Build Operator dashboards tailored to specific operation (InTouch, .NET controls)

  17. Faster Changeovers – One Version of the Truth • Electronic Bills of Material & Specifications • Centralized administration with version control

  18. Faster Changeovers – Accurate Equipment Setup • Site Specific Product Specs • Auto Download of Set Points

  19. Faster Changeovers… Better Operator Visibility • Powerful Set of .NET Controls for Building Operator Displays • Flexible Display Options • InTouch • Operator • Third Party HMI • Web

  20. Respond Faster to Production Issues via Planned vs. Actual Production Values • Electronic management of Work Orders • Ability to change job prioritization & sequencing via Operator displays & job summary .NET Control • Recording of production events • Material consumptions • Complete “as built” records per work order • Immediate detection of deviations • Specification or plan deviations • Real-time database captures full production data record • Active alarm management system • Equipment & material

  21. Planned vs. Actual Production • Online Work Order Management • .NET Controls used in Operator Displays • Visibility to Planned Values • Summary of Planned vs Actual Production

  22. Reduce Production Errors & Increase Yield • Consistent interpretation of operating guidelines and procedures • Accurate paperless execution of work orders & jobs • Show work instructions, SOPs, drawings, NC programs • Central, detailed definition of user privileges and security roles • Assign user rights per entity or process • Job based login • Common security definition using ArchestrA security, including Operating System integration • Central definition of process and product parameters • Electronic Bills of Material • Define processes, specifications, Classes

  23. Execution of Work Orders • Create a Process • Create a Work Order from the Process • Start and Monitor the Status of a Work Order

  24. Central Definition of Process & Product Parameters • Electronic Bills of Material • Specifications • Processes

  25. Operations Premium Edition - Functional Overview Operations Premium Operations Standard Work Order Execution Specifications Bill of Materials • Improve Inventory Turns and Reduce Inventory Cost • Accurate recordkeeping, visibility • Reduce Order Lead Time • Dynamic allocation of production assets • Enforcement of production rules / steps • Reduced Time-to-volume for New Products • Map entity model, product / process context • Improved Compliance & Governance • Electronic system records, history Parameters Download Data Collection Inventory Certifications Labor Management Steps

  26. Improve Inventory Turns & Reduce Inventory Costs via Accurate Records and Increased Visibility • Accurate records of actual material consumptions and production levels • Automatic data collection • Broad inventory mgt functionality; receiving, shipping, scrap, hold, transfers, splitting/combining, re-classifying lots • Detailed definitions of materials • Bills of Materials • Material substitutes • Status information on raw materials, Work in Progress (WIP) & finished goods • Immediate access to real-time inventory status

  27. Reduce Production Lead Time through Dynamic Allocation of Production Assets • Electronic production order management • Ability to perform prioritization & sequencing • Enforcement of production rules • Flexible operational planning based on accurate, detailed information • Actual production resource information • Dynamic allocation of production assets • Based on actual availability of material, equipment or personnel

  28. Reduced Time to Volume for New Productsvia Enforcement of Production Rules • Rapid binding of process capabilities and product definitions • Integration of ArchestrA plant model with Operations’ production model • Detailed definition of sequencing of operating activities • Manual/auto tasks • Steps (procedures) • Accurate records for cycle times, yields, consumptions during initial production runs • Common system environment for model definition, execution and operations • Ability to define Process “State” as experimental or production • Ability to Certify resources according to defined process “State”

  29. Improved Compliance & Governance via Complete Production Records • Complete electronic system records for production, quality and processes • Rapidly respond to unforeseen events, such as product recall or audits (internal, external) • Internal process harmonization • Share best practices and scale across multiple installations • Help ensure safe operations with enforcement of SOPs • Comply with environmental, health and safety standards

  30. Genealogy & Traceability Reporting • Operations Software’s complete data record & easy retrieval make responding to governmental information requests straightforward & easy

  31. Summary • Comprehensive MES Functionality • Bill of Material, Work Orders, Events, Data Collection, Specifications, Set Point Download, Inventory, Certifications, Steps/Procedures, Labor Management, User Management, Genealogy, Traceability, Web Reporting • Fully Scalable • Functionality – Standard & Premium Edition, Supply Chain Connector, MES Clients • Physical Scalability – equipment, lines, plants • Highly Integrated • Wonderware Connectivity • Historian, System Platform MX, OPC, Suite Link • Wonderware’s System Platform • Single Industrial Application Development Environment • Wonderware InTouch • World’s leading HMI

  32. Software Solutions for Real-Time Success SM

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