MES

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MES System at IBV Hungary Ltd. at

Kiskunfélegyháza

Nowadays each manufacturing company has to face highly competitive

business environment which requires shortened manufacturing series,

parallel broadened range of products to fulfill costumers’ requirements.

Costumers’ demands are changing rapidly, delivery periods are short.

Based on economic aspects there is a need of reduce inventory turnover

and decrease inventory supply. This special business environment sets

crucial requirements to the stabilization of production and logistical

processes. In order to have a good grip on all the processes and to reach

the highest exactitude, it is needed to update data of the applied

integrated management systems as often as possible. For this purpose it

is needed to apply automated methods instead of manual data input.

To reach and maintain optimized costs and the highest quality of

products, it is essential to set and supervise the key indicators of the

manufacturing process continuously.

At the beginning of 1980’s, multinational automotive companies already

started to develop manufacturing-execution-control software

systems. These are the so called MES - Manufacturing Execution

System - in the international terminology. Practically, MES is a

controller computer system, which provides real-time supervision of

the manufacturing process. The System provides information of

production order status, demand for materials during production,

breakdowns, production waste, utilization of production device

capacities, scheduled maintenance periods and operational hours. The

priceless service of MES is the settlement of the data collected from the

production processes which are running parallel, the provision of totted

information for the production leaders and operators, all in all the

support and acceleration of the necessary decision-making and

execution.

The IBV Hungary Ltd., with the creative assistance of ScadaSys Ltd.

developed and launched an MES System customized according to IBV

commercial aspects to support the production in its’ Press and

Thermoplastic workshop.

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Currently, in the elaborated system, 40 press machines and 3 moulding

machines are connected to the network of the MES server. During the

creation of the system there has been raised a need for exchanging, in

this way modernizing the PLC controllers of the press machines. Now

these new controllers ensure the highest possible data-access for the

MES system.

The developed MES System at IBV Hungary Ltd. supports the

following business processes:

• PRODUCTION PLANNING / PURCHASING PROCESSES

For the higher transparency of rough plans and production orders

it provides a graphic surface for the planners. In the planning it

utilizes the real-time data of SAP master data by the help of a

specifically developed MES-SAP interface. The plans, created

by the planners, are also recorded in SAP. The benefit of this

approach is that the both systems use the same raw data, which

only have to be updated by the industrial engineers in the SAP

system. Row material needs are calculated and purchased based

on rough plans.

• RESOURCE ALLOCATION AND STATUS FOLLOW UP

Manpower need is calculated automatically by the system. It

highlights the positive (overhead) and negative (manpower need)

differences based on the actual headcount. It observes disposition

of tools (like machine tools, gauges…) while allocating them.

• COST CONTROL / FACT PRODUCT POST CALCULATION

Beside the cost calculations based on collected data, like scrap

cost, the MES ensures the actual data through the interface for

the controlling and for the post-calculations of the product.

• MAINTENANCE MANAGEMENT /

MACHINE STATUS FOLLOW-UP

The MES records the production events in order to follow the

different machine operations; by whom and what was made.

Machine statuses and status of planned maintenances are shown

in text and with different colors to achieve fast reaction of

production and maintenance department.

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• HUMAN RESOURCE MANAGEMENT/

IDENTIFICATION OF AUTHORIZED RESPONSIBLE EMPLOYEE

By the authorization boundary of handling levels it achieves the

secure use of tools and devices. The devices always have a

responsible operator. Identification of the user and the worked

hours are always documented automatically.

• PROCESS MANAGEMENT

o RECORDING OF PRODUCTION PARAMETERS /

PRODUCT TRACKING AND GENEALOGY:

It records actual production parameters with dates in case of every

single product.

There are different levels of technology and production parameter

settings to achieve continuous accepted product quality. That way

original production parameters and further modifications are

followed. It is possible to start new production with the latest

modified parameters or you can use original parameters.

Employee can reduce the necessary time of product change by

using multi-level parameter handling. New production startup will

be quicker and precise.

o SCHEDULING OF PRODUCTS CHANGE OVERS

Product exchange requires cooperation between different

departments at IBV. With scheduling the exchanges became

proposed, it became possible to plan the necessary duties. The

exchange according to the SMED – Single Minute Exchange of

Die, Lean method for the execution of fast switches- became

permanently measurable and developable. It is important to note

that before the introduction of the system there were lot of

changes led by quick decisions. Execution of these exchanges took

too long because of that fact. There was no time to plan and

finalize exchange initiative preliminary activities. It overloaded

the executor. Production scheduling helped to decrease

overloading of participants of production process and that

supports production start ups to be more stable and finalization of

plans according to plans.

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• EFFICIENCY ANALYSIS

o PRODUCTION PLAN AND FACT DATA FOLLOW UP

The execution status of orders can be seen on the graphic surface,

both in the points of time and fulfillment of the orders.The system

gives feedback to the employees directly next to the machine about

their achieved performance; it shows the hourly plan and the

actual number of items each hour. It compares the technological

cycle time to the time performed by the employee. It accelerates

the work of the team leaders with the simplification of the

exploration of differences. They don’t have to spend time with

collecting data, but understand and extinguish/terminate the

causes of differences. The collected data is manageable directly on

the LMPS – Lean Performance Management System – boards placed on the

machines.

o OEE – OVERALL EQUIPMENT EFFICIENCY - /

MEASSURING OF PRODUCTION SYSTEM EFFICIENCY

Aviability, performance and yield factors are defined separately.

On that way it is possible to identify area what needed to

improve.

o OTHER MEASURED DATA, DOCUMENTATION AND FOLLOW-UP OF

MEASURED DATA

It is possible to connect measuring devices to the system through

PLC. As a key indicator IBV Hungary Ltd meassure weight of the

raw material in case of every single product. Weight data are

collected and analysed by the system.

• QUALITY MANAGEMENT

o IMMEDIATE ACTIONS WHEN NEEDED / CORRECTIVE ACTIONS

Continuous visualization of summarized data support immediate

actions when needed. The employee interface surface also

provides an opportunity for the usage of the Andon technique.

o SCRAP OVERVIEW

The employees record the data about waste with the error type.

Shift leaders follow scrap data on Pareto diagrams.

These data are the basis of continuous corrective actions.

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• DATA ACQUISITION

Collected and analyzed data are available and usable for

everybody over WEB based reporting Server. It helps and makes

faster the communication flow between different departments.

MES software and human interface touch screen on the machines

are available in three different languages: Hungarian, English and

German.

• RECORDING OF DATA

Data collection is automated, so human error is impossible (Poka-

Yoke).

When we summarize the results of the MES system we should also

consider the fact, that the data collected and analyzed by the system is a

good basis for further and continuous development and improvement of

the production process in addition to the wide range of techniques of the

management. Such a newly introduced information system has a huge

impact on the business processes, on the internal information flow, on

the whole business structure and also on the corporate culture and

values. During the establishment of this system we should be aware of

these factors and revise the relevant processes and scope of activities. We

have to create the new environment required by the new system and

determine the new tasks and responsibilities. We have to ensure

educated and motivated human resource.

IBV Hungary Ltd stabilized its production processes by implementing

MES system. The results of the investment are positively valued, and

further development opportunities are considered in order to achieve

better business efficiency.

14.12.2013, Kiskunfélegyháza

…………………………….

Lajos Szántó

IBV Hungary Ltd

Production Chief Officer