Manufacturing Execution System – MES
The Manufacturing Execution System (MES) is an online integrated computer-aided system that collects all methods and tools used in production. It was first used in 1990.
MES Performs Four Fundamental Functions:
- It collects real-time data from the production field . (e.g., machine downtimes).
- It organizes the data and stores it in a central database (integrated back and forth with ERP) .
- It ensures that all data, including critical data from other information systems where planning and engineering office data are stored, is accessible over the network.
- It receives job orders from ERP, organizes them, and transfers them to production units. It also responds to events with real-time detailed planning to increase efficiency and quality.
MES tracks all movements in production from raw material to finished product with the help of information technology. Job orders are serviced by ERP to the equipment the operator is working on through MES. Instead of taking information from the operator, it takes inputs from tools and equipment integrated on the machine, PLC software of the equipment, or panels, and transmits it to the ERP system and Andon panels, thereby reducing the time for distributing and collecting information and minimizing errors.
Data collection panels integrated onto the machine communicate with production tools like machines, presses, and injection machines through I/O cards (input-output cards) .
Benefits of Using MES
- Reduces manufacturing cycle time.
- Decreases setup/procurement time.
- Completely eliminates or reduces the time spent on data entry.
- Improves product quality.
- Eliminates or reduces the need for documentation between shifts.
- Improves the planning process.
- Increases the efficiency of factory workers.
- Prevents loss of documents.
- Reduces the number of products waiting to be completed.
- Enhances customer service.
Functions of MES
- Real-time Data Collection from the Production Field
- Performance Analysis
- Reporting based on the collected data in the desired format
- Distribution of tasks to production units
- Job/detailed planning
- Maintenance management
- Workforce management
- Quality management
- Process management
- Product tracking and genealogy
- Resource allocation and status determination
Main Functions of MES
- Planning System Interface
- Data Collection
- Job Order Management
- Workstation Management
- Stock Tracking and Management
- Material Flow Tracking
- Exception Management Production
Reinforcement functions of MES
- Maintenance Management
- Time and Continuity Management
- Statistical Process Control
- Quality Assurance
- Process Data and Performance Analysis
- Document and Product Management
- Product Tracking and Genealogy
- Supplier Management
A Standard MES System Consists of the Following Components:
- Data monitoring and software
- Central hardware . (server)
- Data collection hardware/software
- MES operation module
- MES performance module
- Operator interfaces hardware
- Reporting system
INFORMATION NEEDS IN THE BUSINESS
A comprehensive Manufacturing Execution System . (MES) meets the information needs in businesses.
- Production Department
- Operators in the business seek answers to the following questions:
- Why is this machine not working?
- Can I measure the machine speed accurately?
- How do this month's downtimes compare to last year?
Engineering Office
Engineers can answer the following questions:
- Are the reference values correct for this control loop?
- Do safety lock limits make process values unstable?
- Do alarms sufficiently warn operators?
Process Engineers
Process engineers answer the following questions:
- Is this machine creating a bottleneck in production?
- How did this driver fail?
- Are my material stocks sufficient?
Quality Department
Quality Assurance personnel ask various questions:
- Did recipe changes affect product quality and quantity?
- Have bearing temperatures and vibrations increased since the last maintenance?
- How many hours were the machines in operation last year?
The MES system to be established will provide the general information listed above and fulfill the specific production tracking requests listed below:
- Detailed production tracking
- Quality management
- Monitoring of operators and other personnel
- Communication and integration with ERP
MES is not MIS
MES should not be confused with MIS . (Management Information System) . MES performs the following functions, which MIS cannot, by creating "artificial intelligence" using the information stored in the system:
- Production,
- Part manufacturing and measurement,
- Managing job order priorities,
- Assigning/reassigning personnel,
- Allocating/reallocating semi-finished products,
- Starting and stopping machines,
- Delivering and collecting semi-finished products to/from workstations,
- Programming/reprogramming production equipment,
- Supplier management,
- Instilling lean manufacturing and Six Sigma thinking into the production process with international best practices,
- Directly improving response time in supply chain management.