FOCUS ON CONTROL TECHNOLOGIES
This visibility will make it possible to increase agility , flexibility and the ability to react to any type of event that may occur during day-to-day operations
Manufacturing Execution Systems ( MES )
A Manufacturing Execution System ( MES ) plans the work based on various optimisation parameters such as criticality of execution and the availability of operators , materials and machines .
“ When a company decides to implement a Manufacturing Execution System ( MES ) solution , it mainly looks to provide visibility for its manufacturing operations and to ensure that it is developed on all levels , for operators , supervisors and management . This visibility will make it possible to increase agility , flexibility and the ability to react to any type of event that may occur during day-to-day operations . Ultimately , it will be capable of analysing how its resources and processes are optimised so it can discover how its organisation can improve Overall Equipment Effectiveness ( OEE ),” explained CAD / CAM / MES / ERP software specialist , Lantek Sheet Metal .
“ There are two key objectives when implementing a solution of this type - defining what information will be recorded during each phase of the production process and ensuring that this information is accurate and completely reliable . This task will involve various types of specialists and systems that will generate vast quantities of information ready for review and analysis . We should not succumb to the false belief that by merely collecting data that this , in itself , will result in an improvement . This is illustrated by the saying : ‘ It ’ s just data . Until you use it ’….” One of the most powerful and direct tools for measuring and analysing whether resources and processes are achieving a desired level of optimisation is to define the Key Performance Indicators ( KPIs ) that are to be calculated from all the data collected . To define the appropriate KPIs , users must take into account several factors :
■ KPIs should be defined to measure the performance of those critical factors that demonstrate whether a business is operating as expected . Users must select very carefully which operations are to be measured to obtain a clear idea of whether they are getting the expected results .
■ Operational aspects that are genuinely under a user ’ s control should be measured . This means those aspects for which users can implement mechanisms for improvement when deviations from expected performance are detected .
■ The method for measuring these KPIs must be completely reliable so that users can be assured that the processes and systems that collect the information related to the KPIs are appropriate and function correctly .
“ The Overall Equipment Effectiveness ( OEE ) metric is one of the most relevant KPIs in production environments where there is intensive use of industrial equipment . This metric reflects the productivity of industrial equipment by using the information collected by the validation systems in the workshop . Calculations are performed using a formula that comprises three factors ,” explained Lantek Sheet Metal .
These three factors are :
■ Availability : This measures the time for which machines have actually been producing , compared to their theoretical availability . This is usually defined by their schedule , first taking into account the time required for scheduled maintenance . Losses for this factor may be caused by breakdowns or unscheduled downtime .
■ Performance : This measures the production volume obtained by a machine compared to its theoretical nominal capacity . Losses for this factor may be caused by decreases in production speeds due to the incorrect
Lantek MES Manager manufacturing execution system for sheet metal applications .
configuration of machines .
■ Quality : This measures the quality of production , comparing the faulty units to the total number of units produced . It is important to carry out a more thorough investigation of this factor to find repeating patterns that help managers to identify the origin of these faults .
“ Combining the results of all of these factors provides a quick overview of the productivity of a workshop . However , data should also be analysed separately and from different perspectives ( for each different machine technology , for specific time periods , work shifts etc .) to identify training problems , malfunctioning equipment or the need to redesign certain processes that have a negative impact ,” added Lantek .
Summary
“ When considering an ERP system versus MRP for a manufacturing organisation , the core competences and historical pedigree of the system must match your business - manufacturing . Getting your hands on the software in a meaningful way prior to purchase is the best ( and only ) way to ensure the product ’ s suitability to your needs ,” explained software specialist , 123insight .
“ The best practice should be to select the ‘ best in class ’ product for the task at hand . If , for example an ERP ’ s accounts facility is lacking or less suited to your business then maybe a better solution is a separate MRP and account system that can interface to each other . Cost also plays an important factor - E may have the lesser value than M in a game of Scrabble , but the exchange of the letters at the front of your chosen information system can have a major impact on your balance sheet without relational improvements to your business ,” it concluded . n
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