Wonderware Operations Software

“Improving Manufacturing Operations”

Terence TanGeneral Manager

MES

Definition according to MESA International:

Manufacturing Execution Systems (MES) deliver information that enables the optimization of production activities from order launch to finished goods.

Manufacturing Execution Systems (MES) deliver information that enables the optimization of production activities from order launch to finished goods.

Definition according to ISA:

The MES layer focus in a group of activities (operations, inventory, quality and maintenance activities) corresponding to Level 3 in the Functional Hierarchy model.

The MES layer focus in a group of activities (operations, inventory, quality and maintenance activities) corresponding to Level 3 in the Functional Hierarchy model.

ISA Model

Business Planning & LogisticsPlant Production Scheduling,Operational Management, etc

Manufacturing Operations & Control

Dispatching Production, Detailed ProductionScheduling, Reliability Assurance, ...

BatchControl

DiscreteControl

ContinuousControl

Level 4

Level 3

Levels2,1,0

Purdue CIM Model

Level 0: Instruments and ActuatorsLevel 0: Instruments and Actuators

Level 1: Real time ControllersLevel 1: Real time Controllers

Level 2: Process Supervisory System(s)Level 2: Process Supervisory System(s)

Level 3: Manufacturing Execution SystemLevel 3: Manufacturing Execution System

Level 4: Enterprise Resource Planning SystemLevel 4: Enterprise Resource Planning System

MES

The MESA model

Labor Management

Dispatching Production

Units

Product Tracking & Genealogy

Quality Management

Operations/Detailed

Scheduling

Maintenance Management

Process Management

Document Control

Resource Allocation &

Status

Data Collection

Acquisition

Performance Analysis

Enterprise Resource Planning

Sales & Service

Management

Supply Chain Management Control

Wonderware MESWonderware 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.

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.

What is Wonderware MES?

Product History

2002

July 2007

October 2007

February 2008

March 2009

Wonderware MES Features

Deliver planned vs. actual production•Electronic Work Order Management•Recording of Production Events•Electronic Work Order Management•Recording of Production Eventsusingusing

Improve process and production consistency

•Centralized Manufacturing Model•Production Rules•Certifications

•Centralized Manufacturing Model•Production Rules•Certifications

usingusing

Improve inventory velocity

•Real time inventory management•Detailed definition of materials, substitutes and byproducts•Bill of Materials

•Real time inventory management•Detailed definition of materials, substitutes and byproducts•Bill of Materials

usingusing

Reduce order lead time•Dynamic prioritization and sequencing•Labor management •Connection to HMI/SCADA

•Dynamic prioritization and sequencing•Labor management •Connection to HMI/SCADA

usingusing

Monitor and analyze production performance

•Downtime•Utilization•OEE

•Downtime•Utilization•OEE

usingusing

Licensing

Wonderware MESWonderware MESWonderware MESWonderware MES

Work Order ExecutionWork Order Execution

Parameters DownloadParameters Download

Production Events TrackingProduction Events TrackingBill of MaterialsBill of Materials

Data CollectionData Collection

InventoryInventory CertificationsCertifications

Labor ManagementLabor Management

StepsSteps

Utilization and DowntimeUtilization and Downtime

OEEOEE

OperationsOperationsStandardStandardOperationsOperations

PremiumPremium

PerformancePerformance

Wonderware MES Architecture

Database ServerDatabase ServerDatabase ServerDatabase Server

MiddlewareMiddlewareMiddlewareMiddleware

ClientsClientsClientsClients

Production DB

COM+ PackageWonderware

MESService

Configurator Supervisor OperatorManager

Factory Connector

Custom.NET App

IIS

Wonderware MES Middleware

Wonderware MES Client

System Requirement - Software

System Requirements - Hardware

► 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 Software…Functional Overview

OperationsOperationsPremiumPremiumOperationsOperationsPremiumPremium

OperationsOperationsStandardStandardOperationsOperationsStandardStandard

Work Order ExecutionWork Order Execution

Parameters DownloadParameters Download

SpecificationsSpecifications

Bill of MaterialsBill of Materials

Data CollectionData Collection

InventoryInventory

CertificationsCertifications

Labor ManagementLabor Management

StepsSteps

► 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

► 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

► 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 Software – Standard Edition

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)

Improve Productivity via faster product or line ‘Changeovers’

Faster Changeovers – One Version of the Truth

► Electronic Bills of Material & Specifications

► Centralized administration with version control

► Site Specific Product Specs

► Auto Download of Set Points

Faster Changeovers – Accurate Equipment Setup

Faster Changeovers… Better Operator Visibility

► Powerful Set of .NET Controls for Building Operator Displays

► Flexible Display Options▪ InTouch▪ Operator▪ Third Party HMI▪ Web

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

Respond Faster to Production Issues via Planned vs. Actual Production Values

Planned vs. Actual Production

► Online Work Order Management▪ .NET Controls used in Operator

Displays

► Visibility to Planned Values

► Summary of Planned vs Actual Production

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

Reduce Production Errors & Increase Yield

Execution of Work Orders

► Create a Process

► Create a Work Order from the Process

► Start and Monitor the Status of a Work Order

► Electronic Bills of Material

► Specifications

► Processes

Central Definition of Process & Product Parameters

Operations Premium Edition - Functional Overview

OperationsOperationsPremiumPremiumOperationsOperationsPremiumPremium

OperationsOperationsStandardStandardOperationsOperationsStandardStandard

Work Order ExecutionWork Order Execution

Parameters DownloadParameters Download

SpecificationsSpecifications

Bill of MaterialsBill of Materials

Data CollectionData Collection

InventoryInventory

CertificationsCertifications

Labor ManagementLabor Management

StepsSteps

► 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

► 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

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

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

Reduce Production Lead Time through Dynamic Allocation of Production Assets

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”

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

Genealogy & Traceability Reporting

► Operations Software’s complete data record & easy retrieval make responding to governmental information requests straightforward & easy

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

Software Solutions for Real-Time SuccessSM