Name: Sumanth Pandith Surendra
Institution: Wichita State University
Institution: Wichita State University
ABSTRACT
Majority of the today’s firms are trying to implement information integration systems with the help of Enterprise Resource Planning (ERP) planning tool for the effective execution of the plan in the shop floor. Manufacturing Execution System (MES) is one such tool used for effective execution in the shop floor. This Paper deals how MES could be used and linked to ERP & six sigma methodology in effective execution & also reducing cycle time, increasing machine productivity & process improvements.
Majority of the today’s firms are trying to implement information integration systems with the help of Enterprise Resource Planning (ERP) planning tool for the effective execution of the plan in the shop floor. Manufacturing Execution System (MES) is one such tool used for effective execution in the shop floor. This Paper deals how MES could be used and linked to ERP & six sigma methodology in effective execution & also reducing cycle time, increasing machine productivity & process improvements.
OVERVIEW OF ERP
ERP being an effective tool in planning and its successful implementation in most of the firm’s have created a great impact in boosting productivity and improving business processes. How far the firm’s have succeeded in implementing ERP and are they successfully executing the plan done with the help of ERP? Answer for this question is no. However effective the planning tool is, the execution in the shop floor does not happen according to the plan because of the changes that occur in the demand and the planning tool will not be responsive to the changes due to which there will not be any synchronization. Hence, ERP is not a closed loop which will help for the effective execution in the shop floor. MES is emerging as an effective execution tool which could be linked to the ERP & other planning tools.
MANUFACTURING EXECUTION SYSTEMS (MES)
MES is a tool used for executing shop floor activities effectively & efficiently as per the plan. It basically executes the production plans from the ERP in the shop floor & also helps in real time coordination of the production process. This real time coordination of the production data to the ERP helps to respond dynamically for any changes in the plan and executes the changed plan very effectively. This eliminates waste and also MES will track the production process while it is in progress and captures the data which could be converted into useful information in real time. The data here could be production report, resource capacity, labor capacity, machine capability. This real time capturing and tracking the production process and giving feedback to the production supervisors & managers for any changes that has to be done makes MES an effective tool for the execution. Overall, MES fills up the gap between the planning & the execution & forms a closed loop from planning to execution by giving feed backs back to ERP. MES mainly focuses on the real time capturing of the product process data or any shop floor data and converts the data into useful information for the production managers to take an effective decision upon the process. This also helps in preventive maintenance of the machines and also helps to improve the process capability of the production process by capturing the real time process data and improving the productivity. MES helps in incorporating changes in the plan happened due to the change in the demand forecast. ERP helps to fulfill the order requirements of the customer & MES helps in changing the production plan being responsive & flexible for changes without hampering the on going production in the shop floor, there by meeting the customer requirements and satisfaction.
MES is a tool used for executing shop floor activities effectively & efficiently as per the plan. It basically executes the production plans from the ERP in the shop floor & also helps in real time coordination of the production process. This real time coordination of the production data to the ERP helps to respond dynamically for any changes in the plan and executes the changed plan very effectively. This eliminates waste and also MES will track the production process while it is in progress and captures the data which could be converted into useful information in real time. The data here could be production report, resource capacity, labor capacity, machine capability. This real time capturing and tracking the production process and giving feedback to the production supervisors & managers for any changes that has to be done makes MES an effective tool for the execution. Overall, MES fills up the gap between the planning & the execution & forms a closed loop from planning to execution by giving feed backs back to ERP. MES mainly focuses on the real time capturing of the product process data or any shop floor data and converts the data into useful information for the production managers to take an effective decision upon the process. This also helps in preventive maintenance of the machines and also helps to improve the process capability of the production process by capturing the real time process data and improving the productivity. MES helps in incorporating changes in the plan happened due to the change in the demand forecast. ERP helps to fulfill the order requirements of the customer & MES helps in changing the production plan being responsive & flexible for changes without hampering the on going production in the shop floor, there by meeting the customer requirements and satisfaction.
Integration of ERP & MES:ERP and MES must be integrated for the organization to perform effectively by reducing the cycle time & satisfying its customers. The critical drivers for the integration of ERP & MES are responsiveness, flexibility & productivity. Integrated supply chain will demand for an effective responsive system & ERP helps in matching customer requirements & to incorporate if there is any change in the demand, it requires a system which should be responsive & flexible for any changes. So, MES helps in being responsive & flexible for the changes. Even Productivity measurement & control has to be done in order to fulfill the demand. MES helps in tracking & monitoring the production in real time and make any changes required to meet the demand.
Impacts after Integrating MES & ERP:
i) Cycle time reduction: cycle time after integration is reduced to 50%.
ii) Reduction in Work in Process (WIP), raw materials & finished goods inventory (FGI).
iii) Setup reduction to 30%, management time scheduling time reduced to 75%.
iv) Finally, customer satisfaction by reducing customer backlog by 90%.
i) Cycle time reduction: cycle time after integration is reduced to 50%.
ii) Reduction in Work in Process (WIP), raw materials & finished goods inventory (FGI).
iii) Setup reduction to 30%, management time scheduling time reduced to 75%.
iv) Finally, customer satisfaction by reducing customer backlog by 90%.
Read more on:
- INTEGRATING MES WITH SIX SIGMA METHODOLOGY FOR PROCESS IMPROVEMENTS
- HOW MES FITS IN THE PLANNING/PRODCUTION CYCLE & THE INFORMATION FLOW BETWEEN THEM
A very well written article and example on process improvement in the industrial sector. Most of the MES (manufacturing Execution Systems) need to be optimized for the processes that are carried on them. I am using a process improvement tool these days know as ProcessModel.
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