Description
Manufacturing Execution Systems: An Operations Management Approach and the accompanying workbook were designed to help manufacturing operations management (MOM) practitioners and students understand how to implement and utilize manufacturing execution systems (MES) to optimize data collection and review, improve process efficiency and ensure/improve product quality to achieve the desired return on investment.
Industry veterans Grant Vokey and Thomas Seubert explain the interactions among the MOM key elements (MES, enterprise resource planning [ERP] and product life cycle management [PLM]) and how MES contributes to a streamlined process that produces quality products.
This book discusses the potential for MES to drive real-time, data-driven performance improvement by expanding on the following concepts:
- How the MES application supports operations planning, analysis and reporting
- How MES identifies quality issues and provides the data needed to determine the causes and resolve the problems
- The full scope of MES planning and implementation and its impact on manufacturing operations
- Designing, configuring and implementing MES systems
- IT concepts related to MES and how they apply to manufacturing operations
- How MES can be applied to Industrial Internet of Things (IIoT)
- How MES data can be used for continuous improvement
Independent learners and engineering students can use this book and workbook as a resource for terminology and the functionality of the systems, models and standards that support manufacturing operations. Industrial engineering instructors can use this set as a foundation for manufacturing courses, including the data structures required to support manufacturing.
Table of Contents
Preface xi
Acknowledgments xiii
About the Authors xv
Chapter 1 Introduction, Overview, and the Current State of Manufacturing 1
1.1 Introduction 1
1.2 ERP Business Process 4
1.3 Product Lifecycle Management Business Process 5
1.4 MES Business Processes 7
1.5 The Manufacturing Enterprise View 7
1.6 The Impact of Manufacturing Regulations 12
Chapter 2 A Functional Overview of MES 15
2.1 Differences between an MES and Other Enterprise Systems 18
2.2 General Outline of MES Functionality (Grouping the MES Functions) 20
2.3 General Support of Operations 23
Chapter 3 Order Execution Management: Details and Benefits 27
3.1 Introduction of Order Planning and Execution 27
3.2 Order Execution before MES 28
3.3 Tracking Order Execution with MES 31
3.4 Additional Concepts 35
3.5 Order Execution Benefits 36
Chapter 4 Material Management: Details and Benefits 37
4.1 Material Management Business Process 37
4.2 Material Management Benefits 45
Chapter 5 Quality and Traceability: Details and Benefits 47
5.1 Introduction to Quality and Traceability 47
5.2 Quality Assurance or Quality Control 48
5.3 Quality Assurance 49
5.4 Quality Control 58
5.5 Traceability 68
5.6 Additional Notes 73
5.7 Quality and Traceability Benefits 74
Chapter 6 Production Monitoring: Details and Benefits 77
6.1 Introduction to Production Monitoring 77
6.2 Production Monitoring before MES 78
6.3 Monitoring Area Details 79
6.4 Production Monitoring Benefits 91
Chapter 7 Continuous Improvement: Details and Benefits 93
7.1 Introduction to Continuous Improvement 93
7.2 Brief Introduction to MES Configuration to Support CI 94
7.3 The CI Program 97
7.4 More on Quality Methodologies 106
7.5 Additional Notes 111
7.6 CI Benefits 112
Chapter 8 New Product Introduction: Details and Benefits 113
8.1 Overview of New Product Introduction 113
8.2 The Operations Processes of NPI 115
8.3 Planning Capacity 117
8.4 Additional Notes 120
8.5 NPI Benefits 120
Chapter 9 MES Architectural Concepts 121
9.1 Introduction 121
9.2 General Architecture 122
9.3 Industry 4.0 and the IIoT 125
9.4 In-Plant (Internal Hosting) versus Cloud versus Edge or Fog Solutions 126
9.5 Autonomous MES 127
9.6 Additional Notes 132
9.7 MES Architecture Concepts Summary 138
Chapter 10 Differences in Manufacturing Models and Their Impact on MES 139
10.1 Introduction 139
10.2 Manufacturing Models 140
10.3 Manufacturing Industries 143
10.4 MES Specifics Table 148
10.5 Summary 148
Chapter 11 Developing an MES Strategy 151
11.1 Introduction 151
11.2 A Refresher on the Benefits of an MES 152
11.3 What Are Your Business and Manufacturing Models? 153
11.4 Who Will Use the MES? 156
11.5 Implementing the MES 156
11.6 Implementing MES Functionality 166
11.7 Interfacing with the Company 171
11.8 Supporting the MES Initiative 174
11.9 Supporting Process Standards 177
11.10 Setting up the CoE 177
11.11 Summary 179
Chapter 12 Current Manufacturing Challenges and Trends 181
12.1 Maintenance of Brownfield Plants and Aging Assets 182
12.2 The Challenge of Greenfield Plants 183
12.3 Globalization 184
12.4 Standards, or Lack Thereof 185
12.5 The Need for Simulation 190
12.6 Implementation of Other MOM Concepts 191
12.7 Trends 191
12.8 Summary 193
Chapter 13 Bringing It All Together and Selecting a Solution 195
13.1 Supporting MOM 196
13.2 Gathering and Analyzing Requirements 200
13.3 Evaluating Solutions 202
13.4 Understanding Data within Operations (Reprise) 203
13.5 Conclusion 205
Appendix: Introduction to Autonomous MES Computing 207
Summary 222
Bibliography 223
Glossary 225
Index 229
