Do you know MESA ? Digitizing the Supply Chain - New Product Development & Introduction (NPDI) MESA unConference May 5, 2014 Platinum Keystone Sponsors

Do you know MESA?

Digitizing the Supply Chain - New Product Development & Introduction

(NPDI)MESA unConference

May 5, 2014

Platinum Keystone Sponsors Gold Keystone Sponsors

http://www.brocksolutions.com/default.aspx

The power of knowing what MESAKNOWSCopyright 2014, MESA International

Format for this Session

• What is an Unconference?• MESA Content to start discussion• MESA Working Group hot topics• Discuss your questions and expertise• Create action items for MESA

Learn from each otherExperience what MESA Knows!


Introductions

Erik Nistad, Mondelez InternationalDirector, Enterprise Business Services,Integrated Supply Chain Standards & Solutions,Vice Chairman, MESA Americas Board

Mike Williams, The Dow Chemical Co.Recently RetiredMESA Americas Board Member at Large

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The power of knowing what MESA KNOWSCopyright 2014, MESA International

Introduction to MESA International

MESA is…

…building bridges-of-understanding from the Plant to the Enterprise

…to drive clarity on the role and value of modern Information Technologiesin production operations


How MESA Delivers

Speaking with the Voice of Industry’s Practitioners

Peer-to-Peer

Global Education Program

Points-of-

View

MESA International:Building Bridges-of-Understanding from the Plant to the Enterprise


MESA’s Working GroupsRecipe Transformation Working Group• Founded in mid-2013• Focused on establishing a common

“language” for transforming a formula or bill-of-material into an executable recipe.

• Open for new members (must join MESA to participate)

• Chaired by Erik Nistad, Director, Enterprise Business Services, Integrated Supply Chain, Mondelez International

• Contact: [email protected]

mailto:[email protected]


Why are we (you) here?


There is a Better Way

• Common Language to define how to make a product• Common meaning and structure for the information• From Laboratory to Pilot Facility to Production

Facility• Between production facilities for technology

transfers• Across production stages


Your Ideal process

• The ideal process has:– Information created only

once– Information is available to

all parts of the company that need it

– Information is guaranteed correct and up to date, and

– Information is understandable by all parts of the company and suppliers


The Real Process

• Unfortunately in the real process:– Information is lost and

must be rediscovered – Groups work on

incomplete information– Groups work on out of

date information– The information is

inconsistently understood– Information is not shared

with suppliers


Enterprise Recipe Management

• Standard Process Descriptions for products for:– Technology Transfers– Site sourcing decisions– Investigations & Studies– MES and Batch Startup– Co-development– Sustainability

• ERM is a STRATEGY not a tool– It is a method for faster technology transfers– It is a method to support faster investigations and better production data

collection– It is a method to reduce the time and effort required to build production

(Master) recipes– Captures site best practices for more consistent multi-site quality


ERM Information

• Information for automated technology transfers• Definition of equipment independent manufacturing

processes• Information for QbD (Quality by Design) Design

Spaces• Information for lean manufacturing studies• Information for multi-site investigations• Information for sustainable manufacturing• Information for contract manufacturing • …


Why ERM

• Increased Regulatory Agency confidence with our processes– Same structure / format across all sites

• Recipe development down to days instead of months

• Consistent approach to recipe development across sites for product transfer

• Faster / More RFT Development

• Will achieve a higher level standardization of manufacturing process – Following industry standards & learning

from others

• Improving site to site knowledge of processes (sharing)

• Supports basis for site to site supply chain evaluation (standardized processes)


The ERM Concept

Standard Process Descriptions for Products

based on

Standard Definitions of Manufacturing Operations

using

Standard Quality Attribute Definitions (CQA, KQA)

and

Standard Process Parameter Definitions (CPP, KPP)

and

Standard Process Report Definitions

ERM


Automatic, Executable Recipe Generation

• Has anyone tackled automatically converting info from NPDI to “executable recipes”?


Three Processes

• Creation of a core set of process actions• Creation of site specific, equipment constraints• Creation of General Recipes


Core Processes Implemented By A Team Of SME’s

• Create a core library of Process Action definitions

• Create a core library of Equipment Constraint definitions.

• Create sample General Recipes for existing products to validate the libraries.

• Maintain the libraries and distribute to the sites and R&D.


Processes Implemented By Site Process Experts (SPE)

• Create and maintain a local library of Recipe Segments that implement the process actions on the site’s equipment.

• Create and maintain the equipment maps that define the layout and material flows through the site’s equipment.

• Create, using the transformation algorithms defined later in this paper, master recipes from the General or Site recipes provided by the core team or R&D.


Processes Implemented By R&D

• Create General Recipes as the definition of how to manufacture a product, using the definitions in the Process Action and Equipment Constraint libraries

• As new processes are developed, work with the SMEs and the SPEs to develop and define additional Process Actions and/or Equipment Constraints.


Output Are Libraries Used In ERM• A Process Action definition library• A library of Process Parameter definitions, used in Process

Action definitions• A library of Quality Attribute definitions, used in the Process

Action definitions• A library of Units of Measure, used in the process action and

Equipment Constraint definitions• A library of Process Report definitions, used in the Process

Action definitions• An Equipment Constraint definition library• Site recipe segment libraries• General recipe libraries


Automation

• With these definitions and libraries it is then possible for software to automate the creation of master to control recipes for a specific site


Questions?

• What do all of you think?

• Does this make sense to you / your organization?

• Has anyone been able to cost justify an ERM type approach?


Barriers To NPDI Introduction And Operational Excellence

Original slides extracted from 2003 MESA report by EDSReference to MESA white paper PLM GuidelinesUpdated for MESA 2014

Mike K WilliamsMESA memberThe Dow Chemical Company – retiredrepresented 2014 MESA –Industry Week UnConference

Acknowledgement:


Typical NPDI Environment

Develop & ScaleProduct

Enterprise Recipe Mgmt

Shop floor Execution

ERP

eBOM missing• Material Composition• Equipment Capability

Design – Planning – Manufacture

Product Scheduling

Process ControlR&D

Supply Chain

Manufacturing


Are these your current processes?

ExecutePlan

Shop Floor

Line 1

Line 2

Line 3

Line n

Design

•Work instructions•ECO’s•Routings•MBOM

•EBOM•Drawings•Models•Specs•ECO’s

1st Transformation 2nd Transformation


Now imagine coordinating a Refinery

http://en.wikipedia.org/wiki/File:RefineryFlow.png


The integrated view

ERPERP

Process Definition

Process Definition

ProductDefinition

ProductDefinition

ShopFloor

Execution

ShopFloor

Execution

• E-BOM• M-BOM• Characteristics• Prod. Configuration

Production Orders

Product ProducedMaterial ConsumedMachine Time utilized

Reconciliation andChange Requests

• Process Configuration• Op. Routing• Work Instructions• Consumables• Characteristics Assignment• Shop-floor Reqs.

• Tooling• Data Collection fields• Operator Certification

Configured work package

The Waltz has three steps:• PLM• POM• OEEEnterprise Recipe Management

- The glue


Benefits of Integrated POM-PLM-OEE• Creates an unambiguous communication

from product and process definition to the point of manufacture

• Configuration management applied to product and process derive work package for a specific work order

• Direct, associative re-use of product definition data right to the shop

• Feed back to design and supply chain planning:– on production performance– Process capability

• Creates an unambiguous communication from product and process definition to the point of manufacture

• Configuration management applied to product and process derive work package for a specific work order

• Direct, associative re-use of product definition data right to the shop

• Feed back to design and supply chain planning:– on production performance– Process capability

• Fast, accurate change implementation

• Delivers the right data, right time and place

• Avoids data re-entry error• Saves time and skilled labor• Expedites Product and

process improvement • Provides improved CAPEX

utilization

• Fast, accurate change implementation

• Delivers the right data, right time and place

• Avoids data re-entry error• Saves time and skilled labor• Expedites Product and

process improvement • Provides improved CAPEX

utilization


More Resources• MESA Whitepaper: June 2013 – “Using General Recipes for Standardized Multiple

Plant Manufacturing Science”• MESA Whitepaper: November 2008 – “Manufacturing Science Model Extensions

to Address Lean Manufacturing and Lean Supply Chain”• MESA Whitepaper: November 2008 – “An Iterative Refinement Approach

towards a Structured Recipe Design”• MESA Whitepaper: March 2008 – “Manufacturing Science Model Extensions to

Address Product and Process Sustainability”• MESA Whitepaper: April 2003 – “General to Master Recipe Transformation,

Capturing Best Engineering Practices in Recipe Generation”• MESA Whitepaper: October 2002 – “From a Corporate Product Specification to a

Control Recipe: It's not a Transatlantic Trip”• MESA Whitepaper: October 2002 – “General Recipe: Multiproduct Facility

Design; Technology Transfer”100s of materials available to Premium members

at no additional charge


Why MESA?Global community for improving Operations Management with IT

Best practices & guidance to drive productivity & profitability

Global Education Program raising competency for production IT success

Facilitate innovation for real-time Plant to Enterprise (P2E) integration

Be heard and drive industry forward

Join the conversation at: www.mesa.org

http://www.mesa.org/


To Improve Your Success…

www.mesa.org



Thanks for Participating!MESA Enterprise Recipe Transformation Working Group

www.mesa.org

Erik Nistad, Mondelez InternationalDirector, Enterprise Business Services,Integrated Supply Chain Standards & Solutions,Vice Chairman, MESA Americas [email protected]

Mike Williams, The Dow Chemical Co.Recently RetiredMESA Americas Board Member at Large

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mailto:[email protected]


Thanks for Participating!

Moderator #2 NameJob Title/MESA TitleContact info

Moderator #3 NameJob Title/MESA TitleContact info

Logo (if applicable)

Logo (if applicable)

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www.mesa.org


Documents

Do you know MESA ? Digitizing the Supply Chain - New Product Development & Introduction (NPDI) MESA unConference May 5, 2014 Platinum Keystone Sponsors