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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