manufacturing execution systems: the isa-95 framework
TRANSCRIPT
Manufacturing Execution Systems (MES)The ISA-95 framework
and MES Subsystem Interactions
Fred Genett
1. Manufacturing Execution System (MES) definition
2. MES Activities3. MES System Levels as defined in ISA-
954. MES System Level Interactions
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Presentation Contents
Manufacturing Execution Systems (MES), are information technology systems that manage manufacturing operations in factories.
The scope of such systems in terms of activities may include:
Management of product definitions Management of resources Scheduling (production processes) Dispatching production orders Execution of production orders Collection of production data Production performance analysis Production Track & Trace
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MES Definition and Scope
◦ Management of product definitionsStorage, version control and exchange with other systems of master data
such as product production rules, bill of material, bill of resources, process set points and recipe data which are all focused on defining how to make a product.
◦ Management of resourcesRegistration, exchange and analysis of resource information, aiming to
prepare and execute production orders with resources of the right capabilities and availability.
◦ Scheduling (production processes)These activities determine the production schedule as a collection of
work orders to meet the production requirements These orders are typically received from enterprise resource planning or specialized advanced planning and scheduling systems.
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MES Activities
◦Dispatching production ordersDepending on the type of production processes this may include
further distribution of batches, runs and work orders, issuing these to work centers and adjustment to unanticipated conditions.
◦Execution of production ordersAlthough actual execution is done by Process control systems,
an MES may perform checks on resources and inform other systems about the progress of production processes.
◦Collection of production dataCollection, storage and exchange of process data, equipment
status, material lot information and production.
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MES Activities (continued)
◦ Production performance analysisCreate useful information from raw collected data
about the current status of production such as Work In Progress (WIP) overview as well as the production performance of the past period for Overall Equipment Effectiveness (OEP) or similar Performance Indicators.
◦ Production Track & TraceRegistration and retrieval of related information in
order to present a complete history of lots, orders or equipment.
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MES Activities (continued)
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Manufacturing Operation System Levels*
*Levels are references to ISA-95, "Enterprise-Control System Integration”
Examples of systems acting on ISA-95 level 4 are:
◦ Product Lifecycle Management (PLM)◦ Enterprise Resource Planning (ERP)◦ Customer Relationship Management (CRM)◦ Human Resource Management (HRM)
To PLM: production test results From PLM: product definitions, bill of operations (routings), electronic
work instructions, equipment settings To ERP: production performance results, produced and consumed
material From ERP: production planning, order requirements To CRM: product tracking and tracing information From CRM: product complaints To HRM: personnel performance From HRM: personnel skills, personnel availability
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Level 4 MES Systems
Examples of systems acting on ISA-95 level 3 are:
◦ Production Information Management System (PIMS)◦ Warehouse Management System (WMS) ◦ Computerized Maintenance Management System (CMMS)
To PIMS: quality test requests, sample lots, statistical process data From PIMS: quality test results, product certificates, testing
progress To WMS: material resource requests, material definitions, product
deliveries From WMS: material availability, staged material lots, product
shipments To CMMS: equipment running data, equipment assignments,
maintenance requests From CMMS: maintenance progress, equipment capabilities,
maintenance schedule
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Level 3 MES Systems
Systems acting on ISA-95 level 2 are:
◦ Supervisory Control And Data Acquisition (SCADA)◦ Programmable Logic Controllers (PLC)◦ Distributed Control Systems (DCS)◦ Batch Automation Systems
Information flows between MES and these process control systems are roughly similar: To DCS: work instructions, recipes, set points From DCS: process values, alarms, adjusted set points, production
results
Plant floor data is first collected and diagnosed for real-time control in a DCS or SCADA system then connected to these Level 2 systems for exchanging plant floor data.
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Levels 1and 2 MES Systems
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The ISA-95 Framework
