Manufacturing Execution Systems (MES)

Entering Work Instructions into 3WS

Hit F5 key, to view in full screen modethen ESC to return to original format.

Wayahead manage many different production & mixing activities within the 3WS program.

3WS has many modules to cover each manufacturing operation. Please review the 3WS module flowchart list in this document.

Specific MES work instruction (WI) functionality, is available across each 3WS module, with flexible setup and data entry options, to cover most production requirements.

This document will take you through some of the 3WS stages, to highlight how different work instructions can be setup and then entered, during actual manufacturing activities.

MES Introduction

MES Work Instructions in 3WS modules

1. Setup formula items – list of MES actions.

You can setup multiple MES activities for the same material.

Different MES actions are managed using configurable UOM setup rules.

This data can also be downloaded, from your ERP system, such as SAP.

1. Setup formula for MES - detail entry screen

Setup the MES work instruction for the same material, with processing rules such as expected yield, tolerances and e-Signature requirements.

This data can also be downloaded, from your ERP system, such as SAP.

2. Dispensing – After dispensing message

The operator records the ‘Exhaust Air Flap %’ during the MES result process. Result of 31% is inside tolerance (30% - 40%), so no eSignature is required.

3WS shows an AFTER Dispensing MES work instruction below. Then the program will print out a barcoded dispensing label, to be scanned during the mixing stage.

3. Manufacturing the earlier dispensed item

Scan the dispensing label barcode for item 1, then manufacture & consume.

3. Manufacturing – MES results processing

When Item 1 is started, the manufacturing instructions PDF document will be displayed and then printed, containing Work Order information.

3WS displays the BEFORE work instruction for Item 1 in this Order.

All comments and target fields can be customised in 3WS, for each separate work instruction.

3. Manufacturing – report is displayed3WS displays the manufacturing document ‘901020.02.PDF’.

Batch number and barcode are added to 901020.02.PDF

The original PDF is opened. Then 3WS adds a Page-Header to the document, with batch number printed and batch number repeated as a barcode.

The operator then prints the complete manufacturing instructions.

3. Manufacturing – during manufacturing

The operator records the ‘Actual Drying Time’ work instruction during manufacturing. The actual value is within the tolerance rules of > 15.

3WS displays the relevant MES work instruction.

All comments and prompt fields can be customised in 3WS, for each separate work instruction.

3. Manufacturing - after manufacturing

The operator records the ‘NET WEIGHT’ yield MES result after mixing the item.

After item 2 is consumed, 3WS displays the AFTER MES work instruction.

Yield will be instantly calculated and displayed.

MES work instructions with actual recorded values are printed on your reports. This forms part of the full electronic batch record (EBR) retained within 3WS. Any over-ride eSignatures, are included against that MES activity.

4. Work Order finished – print final report

MES considerations and benefits

• Before & After MES work instructions can be setup by item

• Available during Dispensing, Manufacturing & Packaging

• Unlimited MES actions can be setup for each item

• Lower & Upper tolerance can be setup for each MES action

• Various validation rules can be setup for each MES action

• Site can download Order MES data from their ERP system

• Full audit trail of eSignatures for outside tolerance values

• Detailed report can be printed out as part of your EBR

• Report layout can be customised for each site

• Screen design can be customised for each site ………

5. Additional screens and report examples

Example of multiple MES actions for one item.

Item=1 EBR after MES Actions are entered

ORDER Detail Report.frx

Example of multiple MES actions for an item, with one over-ride

Item=14 EBR before MES results are entered

Example of EBR report, PRIOR to recording of actual consumption data for Blending, Net weight & the final Reconciliation formula.

Item=14 EBR after MES results are entered

Example of completed Blending, Net weight & Reconciliation data.Note: all report layouts and contents can be customised onsite.