MES Business Process Study

Manufacturing Execution System

Assessment and Roadmap Project

Meeting Agenda• Introductions

• Project Objectives

• Project Scope

• Project Method / Approach

• Boston Scientific Participation

• Outcomes / Deliverables

• Proposed Workplan / Schedule

• Questions / Answers

• Wrap-Up: Action Plan / Next Steps

Meeting Context

• Introduction & Explanation of Project

• Establish Common Understanding

• Set Expectations

• Refine Project Work Plan to Fit Stakeholders & Organizational Environment

• This is an Interactive session – Questions are Welcome and Encouraged

Project Objectives

• Definition of Future State Business Functions and Processes

• Create Consensus for Necessary Transformation

• Establishment of Roadmap for Migration

Project Scope

• Manufacturing Assessment– S95 Business functions impacting production– Planning and Scheduling through Shipping– Review As-Is Materials– Develop Future State To-Be Processes

• Gather information for all appropriate Production Sites

Project MethodsMES Assessment - 1

Project Kick-Off Strategy & Goals As-Is Definition S95 Requirements Prep S95 Requirements Analysis

Activitie

sA

ctivitie

s

Prepare Requirements Document

Review Manufacturing As-Is Architecture

AS-IS DEFINITION

Project Roadmap Presentation

Conduct Strategy Interviews

REQUIREMENTS ANALYSIS

Identify Enterprise Problems and Opportunities

REQUIREMENTS ANALYSIS

PREPARATION

Analyze S95 Survey Results

Identify Plant Level Problems and Opportunities

STRATEGY & GOALS

PROJECT KICK-OFF

Conduct Requirements Analysis

Distribute S95 Surveys

Prepare Requirements Analysis Materials

Analyze Strategy Interview Results

S95 Presentation

Review St. Paul As-Is Material

Confirm/Modify As-Is Models with Clonmel and Dorado

Project MethodsMES Assessment - 2

Process Workshop Prep Process Workshops To-Be Architecture

Activitie

sA

ctivitie

s

Generate To-Be Process Flows

Prepare System to Function Mapping Document

Conduct Data Walkthrough Workshop

Prepare Requirements Mapping Document

Prepare Initiatives Mapping Document

Cost Benefits Analysis

Prepare S95 To-Be Workshop Materials

TO-BE ARCHITECTURE

Review Problems and Opportunities

Prepare Baseline S95 Process Maps

Identfiy Interfaces / Information Flow

Prepare S95 End-to-End Map

Best Practice Recommendations

TO-BEROADMAP

System Acquisitions Roadmap

Conduct S95 Workshops

Conduct Process and Architecture Review

Prepare Strategy and Objectives Mapping Document

TO-BE PROCESS WORKSHOPS

TO-BE PROCESSWORKSHOP

PREPARATION

To-Be Roadmap Presentation

To-Be Roadmap

Customer Participation

• Sharing of Data and Materials• Proactive Participation in Individual / Workshop

Discussions– Strategic Plans– As-Is Process Reviews– Surveys and Requirements Sessions– To-Be Process Workshops

• Support at Production Sites• Collaboration in Working Sessions• Final Project Recommendations Session

Deliverables

• Review of Current State– Process Disconnects / Gaps– Opportunities for Improvement

• Future State (To-Be) Manufacturing Processes– Strategy & Objectives– Requirements Definitions– Process Maps

• Roadmap and Migration Plan – Business Functions to Systems Footprint– System Acquisition Strategy and Roadmap– Best Practices Recommendations– Cost Benefit Analysis

Proposed Work Plan

• As-Is Material Review for affected Production Sites

• Requirements Sessions with Function Owners• To-Be Process Workshops at Production Sites• Refinement and Review of Process Maps• Collaboration in Generation of Final Deliverables• Review of Recommendations and Roadmap

Why Use S95?

• Widely available and accessible standard confirms credibility of approach.

• Complete and comprehensive categorization of manufacturing functionality

• Body of existing documentation and templates to support execution

What is S95?

Procurement(5.0)

ProductionScheduling

(2.0)

Material andEnergy Control

(4.0)

ProductInventory Control

(7.0)

Product CostAccounting

(8.0)

QualityAssurance

(6.0)

ResearchDevelopment

and Engineering

Short

Term

Materia

l and

Energ

y Req

uirem

ent.s

Mat

erial

and

Energ

y Inv

ento

ry

Maintenance PurchaseOrder Requirements

Product and Process

Know How

Product and Process

Information R

equest

QA Results

Standards QA

Res

ults

Produ

ctio

n C

ost

Obj

ectiv

es

ScheduleCapacity

Produ

ctio

n Per

form

ance

and

Costs

ProductShipping Admin

(9.0)

OrderProcessing

(1.0)

Process Data

Production From

Plan

Mat

eria

l and

Ene

rgy

Rec

eipt

(Inc

omin

g)

Material and

Energy O

rder

Requirem

ents

Marketing& Sales

Standards and

Customer

Requirements

Pro

duct

and

Pro

cess

Req

uire

men

ts

Incoming

Confirm

ation

Finished GoodsWaiverFinished Goods

Inventory

ProductionControl

(3.0)

Process DataLong

Ter

m M

ater

ial a

nd

Ener

gy R

equi

rem

ent.s

Pack OutSchedule

Rel

ease

To S

hip

Con

firm

To S

hip

In-ProcessWaiver Request

What is the S95 Scope?

• The definition of the scope of the manufacturing control domain

• A definition of the functions associated with the interface between control functions and enterprise functions

• A definition of the information which is shared between control functions and enterprise functions

S95 & S88 Hierarchy

DefinedIn S95

Business Logistics SystemsPlant Production Scheduling

and Operational Management

Level 4

Manufacturing Control SystemsArea Supervision, Production

Scheduling, Reliability Assurance

Level 3

BatchControl

Systems

DiscreteControl

Systems

ContinuousControl

Systems

Levels2,1,0 Defined

In S88

How are the Models Used?

• S95 Used to Define:– Business Requirements– Business Functions and Processes– System/Functional Architecture– Business Transactions


INVENTORYOPERATIONS

MANAGEMENT

INVENTORYOPERATIONS

MANAGEMENT

MAINTENANCEOPERATIONS

MANAGEMENT

PRODUCTIONOPERATIONS

MANAGEMENT

QUALITYOPERATIONS

MANAGEMENT

Procurement(5.0)


(2.0)


(4.0)

ProductInventory Control

(7.0)


(8.0)

QualityAssurance

(6.0)

ResearchDevelopment

and Engineering


(9.0)

OrderProcessing

(1.0)

Marketing& Sales

ProductionControl

(3.0)

MaintenanceManagement

(10.0)

OrdersSession

SchedulingSession

ProductionSession

QualitySession

To-Be Process

Dept/Systems Footprint

Interfaces

RequirementsMap

Process Workshops from Selected S95 Functions


Session Deliverables

Order Processing (1.0) Function Desired Practice Requirements Notes a) customer order handling,

acceptance, and confirmation b) sales forecasting c) waiver / reservation handling d) gross margin reporting e) determining production orders

Corporate1will continue to manage customer orders and gross margin reporting with current systems. [WS] Item (b) will be addressed by a separate effort. [TS, TM] Item (e) will be addressed through the use of plant-level finite scheduling. Production orders will be generated at each step of the production process – slurry batching, finished product batching, and packaging (filling through finishing).

1.1 The master shop orders for tracking and tracking will be maintained in BPCS. 1.2 The master production models and bills of material will be maintained in BPCS. BOMs will be downloaded from BPCS to the execution layer for production. 1.3 [TS, TM] Handoff of inventory from production to distribution will be managed with a BPCS transaction into the warehouse management system (TBD). 1.4 [TM] Each batch (slurry or RTD finished product) shall be assigned its own shop order. 1.5 [TS, TM] Each finished-goods SKU production run will be assigned its own shop order.

Assumption: a Corporate2-like third party warehouse and distribution management approach will be employed in Plant2.

To-Be ProcessDept/Systems

FootprintInterfaces

RequirementsMap

1.4 Plant Locks Process Orders

1.3 Plant Reviews and Adjusts the Process Orders

Start

1.1 Oracle Creates

Production Schedule

1.2 Oracle Releases Process Orders to

MES

End

FP-1.0 Order Processing

Functional Processes (S95 Functions)

Mapped Requirements Drive To-Be Process



FootprintInterfaces

RequirementsMap

1.4 Plant Locks Process Orders

1.3 Plant Reviews and Adjusts the Process Orders

Start

1.1 Oracle Creates

Production Schedule

1.2 Oracle Releases Process

Orders to MES

End

FP-1.0 Order Processing

WaxWax/Core

Die

Monoshell

Mold

Foundry

Mold

Alloy

Knockout

Cast Produ

ct

Ceramic

Crucible

Cast

Casting Material

s

Metal Cleaning

Functional Processes (S95 Functions)

Operational Processes (S88 Processes)Lot Create

100

0501 Receive &

Inspect

200

0509 Inject

Components

300

0329Inspect

Components

400

0344

Wax Die

Work Instructions &

Product Criteria

FP 3.1 – Lot Tracking

FP 5.2 – Spec Mgt

FP 5.2 – Spec Mgt

Part Dimensions

Combined Processes


S95 and S88 Process Flows show complete manufacturing process




FootprintInterfaces

RequirementsMap

Lot Create

100

0501 Receive &

Inspect

200

0509 Inject

Components

300

0329Inspect

Components

400

0344

Wax Die

Work Instructions &

Product Criteria

FP 3.1 – Lot Tracking

FP 5.2 – Spec Mgt

FP 5.2 – Spec Mgt

Part Dimensions

Function Transaction Source Dest Method Trigger/FrequencyTransactionSize Data Elements

Production Scheduling (2.0) Master Schedule Issue Oracle MES Oracle API Daily 6 KB FG ItemQuantityCustomer PO #Plant LocationRequest DateOrder Priority

Production Scheduling (2.0) Master Schedule Update MES Oracle Oracle APIManual - Production Schedule Completion 1 KB Commit Date

Material Control (4.0) Raw Material Request MES Oracle Oracle APIManual - Production Schedule Completion 3 KB Material Item

QuantityScheduled Date

4

Casting

Preheated Mold

Cast Log· Temperature· Vacuum· Pouring Time· Heat ID· Charge Weight

Metal Casting

Casting Results

Melt Profile· Job Number

Cast Set-up· Job Number· Lot Number· Serial Number· Quantity· Date/Time· Operator ID

Crucible Rating· Crucible Number· QC Data· Lot Number

Alloy Charge· Heat Number· Supplier QC Data

Combined Processes

Transaction Details

High-Level Transactions are Identified




FootprintInterfaces

RequirementsMap

OrderProcessing

(1.0)

QualityAssurance

(6.0)

ProductInventoryControl(7.0)


(8.0)


(9.0)

MaintenanceManagement

(10.0)


(2.0)

ProductionControl(3.0)


(4.0)

Procurement(5.0) Research

Development andEngineering

Marketing & Sales

Co

nfirm

To S

hip

Re

lea

se T

o S

hip

Pro

duct

i on O

rder

sA

vail a

bilit

y

Long

Term

Mat

eri a

l

and

Energ

yR

equi

rem

ents

Material and

Energy

Ord

er Require

ments

Inc

oming

Order C

onfirmation

Maintenance Purchase Order Requirements

Pro

duct

ion

Cos

t Ob

ject

ives

Pro

duct

ion

Per

form

ance

and

Cos

t

Material and Energy Inventory

Short Term Material and Energy Requirements Process Data

Production Capability

Standards and Customer Requirements

Process DataMainte

nance

Technical Fe

edba

ck

Main

tenan

ce Respo

nses

Main

tena

nce Requ

ests

Main

tenan

ce Metho

ds and

Standard

s

Product and Process Know How

Product and process Technical Feedback

Product and Process Information Request Produ

ct an

d

Proce

ss

Req

uirem

ents

Standards and

Customer

Requirements

QA

Res

ul t s

Finished Goods Waiver

Human Resources

Production From Plan

Schedule

Incoming Material and

Energy Receipt

Pack Out Schedule

Finished Goods Inventory

In Process WaiverRequest

QA Results

ERP

ERPCRM

CRM

MES/LIMS

Functions Are Mapped to Best Practice Systems

As-Is/To-Be Process Map7.1 Finished Goods Inventory Transfers

7.1.

3.2

ME

S –

LP

N to

LP

N7.

1.3.

3M

ES

– F

G to

WIP

Tea

mce

nter

7.1.

3.1

ME

S –

Fin

ishe

d G

oods

Sta

ndar

d P

roce

ssE

RP WIP08

WIP Assembly Return

WIP07WIP Assy

Completion

2Last production

operation

3Separate returned

items from standard production

7Check MRB’s

(1.1 MRB Management)

11 & 12Print Label and Apply to LPN

(3.8 Label Mgt)

9 & 10Generate WIP to FG Transaction

6Verify Quality Data

WIEWork Instruction

Explorer

8Move Item(s) to appropriate LPN

22Enter item

transfer in MES Form

21Get item, source, and target LPN

numbers

31Generate FG to WIP Transaction

30Remove Item(s)

from LPN

13Move Item(s) to

FG Area

34Item(s) goes through WIP

Inventory process

24Reconcile MES LPN Numbers

1Review lot traveler for item(s) in the

lot

5Get LPN Number

(MES Internal)

15Item LPN-to-LPN

Change

23Move Item(s) to appropriate LPN

28Move Item from

FG to WIP

29Get item, source

LPN numbers

32Reconcile MES LPN Numbers

33Reconcile MES WIP Inventory (MES Internal)

4Review Work Instructions

(3.2 Work Instruction Handling)

High Level Architecture

Avid Solutions Proprietary and ConfidentialCopyright © 2009 Avid Solutions Inc. All Rights Reserved

Economy & Finance

MES Business Process Study