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Automation and Drives Manufacturing Execution Systems Simatic IT Manufacturing Execution Systems SIMATIC IT © Siemens A&D AS MES1 SCM Manufacturing Execution.

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Presentation on theme: "Automation and Drives Manufacturing Execution Systems Simatic IT Manufacturing Execution Systems SIMATIC IT © Siemens A&D AS MES1 SCM Manufacturing Execution."— Presentation transcript:

1 Automation and Drives Manufacturing Execution Systems Simatic IT Manufacturing Execution Systems SIMATIC IT © Siemens A&D AS MES1 SCM Manufacturing Execution Systems As with Business Systems, ERP manufacturers have integrated and extended functions outside the Enterprise … many functions are required…  Between Business and Controls level, Inventory Invoicing Bill of Material Shipping Accounting Order Mgmt. Receiving Controls DCS HMI CNCPLC Production data collection Production execution Production resource management Production dispatching Production tracking Detailed production scheduling Product definition management Production Performance analysis MANUFACTURING EXECUTION SYSTEMS ERP... a new layer is needed to work together with CONTROL to manage properly the PLANT

2 Automation and Drives Manufacturing Execution Systems Simatic IT Manufacturing Execution Systems SIMATIC IT © Siemens A&D AS MES2 CONTROL What do you need to manage? ERP Production data collection Production execution Production resource management Production dispatching Production tracking Detailed production scheduling Production schedule Product definition management Production Performance analysis Product definition Production capability Production performance  WHAT and HOW to produce  What CAN be produced  When and What TO produce  When and What WAS produced Product Definition Production Capability Production Schedule Production Performance "From ISA , Part 3 (Draft 11). Copyright ISA 2003.” This is defined by ISA S95 (IEC/ISO 62264): the international standard for MES

3 Automation and Drives Manufacturing Execution Systems Simatic IT Manufacturing Execution Systems SIMATIC IT © Siemens A&D AS MES3 CONTROL What do you need to manage? ERP Production schedule Product definition Production capability Production performance "From ISA , Part 3 (Draft 11). Copyright ISA 2003.” Download of Material Master Data Incoming Goods Management Download of new Production Orders Orders Dispatch Manual operations Batch Execution Quality Management KPI Management Material Tracking & genealogy.... Production data collection Production execution Production resource management Production dispatching Production tracking Detailed production scheduling Product definition management Production Performance analysis

4 Automation and Drives Manufacturing Execution Systems Simatic IT Manufacturing Execution Systems SIMATIC IT © Siemens A&D AS MES4 SIMATIC IT Framework SIMATIC IT Component SIMATIC IT Component SIMATIC IT Component SIMATIC IT Component SIMATIC IT Component SIMATIC IT Component SIMATIC IT Component SIMATIC IT Component SIMATIC IT Component SIMATIC IT Component Production Operations explicitly represent the rules that drive the components and create a whole solution SIMATIC IT Framework SIMATIC IT Component SIMATIC IT Component SIMATIC IT Component SIMATIC IT Component SIMATIC IT Component SIMATIC IT Component SIMATIC IT Component SIMATIC IT Component SIMATIC IT Component SIMATIC IT Component SIMATIC IT approach

5 Automation and Drives Manufacturing Execution Systems Simatic IT Manufacturing Execution Systems SIMATIC IT © Siemens A&D AS MES5 Business Benefits Business Benefits Corporate approach: Standardization across multiple sites Capitalization of know-how: modeling and re-using the Corporate best practices (business and production rules) Reduction of solution costs, risk and implementation time EC Regulation 178/2002: implementing Food/Feed traceability/genealogy (critical for product re-calls) Integration of Legacy Systems/Third Party Products Satisfying Customers with SIMATIC IT

6 Automation and Drives Manufacturing Execution Systems Simatic IT Manufacturing Execution Systems SIMATIC IT © Siemens A&D AS MES6 Satisfying Customers with SIMATIC IT Production Benefits Production Benefits Production Tracking: Order and Batch tracking Material tracking Personnel management during production KPI management Scraps and rework management Exception management: Realtime reaction to any production event and readjustment of production process Manual operations management and tracking Plant Performance Analysis  Production optimization

7 Automation and Drives Manufacturing Execution Systems Simatic IT Manufacturing Execution Systems SIMATIC IT © Siemens A&D AS MES7 IT Benefits IT Benefits Easy and effortless insertion of new equipment thanks to the library concept Easy and effective modification to the business process Minimal skill required to develop projects: SIMATIC IT modeling and graphical approach Easy know-how transfer on a project (for instance System Integrator -> Final Customer) Fast troubleshooting Satisfying Customers with SIMATIC IT Flexible solutions, with reliable products: Products = thoroughly tested functionality in components Flexibility is granted by: easy implementation of project specific data, which need to be exchanged between ERP and Control The Framework approach grants a full flexibility in implementing the business logic

8 Automation and Drives Manufacturing Execution Systems Simatic IT Manufacturing Execution Systems SIMATIC IT © Siemens A&D AS MES8 Satisfying Customers with SIMATIC IT Seamless Implementation process: Customer provides the Project description Prototype with SIMATIC IT: Plant modeling, business process modeling The “core” of the final solution may be shown to the customer in a short time in a quite intuitive way Final solution with SIMATIC IT: gradual transition from Prototype to final solution by adding the needed engineering SIMATIC IT approach allows/forces to focus on: Modeling the real Production issues and business process

9 Automation and Drives Manufacturing Execution Systems Simatic IT Manufacturing Execution Systems SIMATIC IT © Siemens A&D AS MES9 Physical Model The heart of the SIMATIC IT system is the physical model

10 Automation and Drives Manufacturing Execution Systems Simatic IT Manufacturing Execution Systems SIMATIC IT © Siemens A&D AS MES10 Physical Model The model describes the capabilities of the machines, applications and people on the plant

11 Automation and Drives Manufacturing Execution Systems Simatic IT Manufacturing Execution Systems SIMATIC IT © Siemens A&D AS MES11 Physical Model The heart of the SIMATIC IT system is the physical model

12 Automation and Drives Manufacturing Execution Systems Simatic IT Manufacturing Execution Systems SIMATIC IT © Siemens A&D AS MES12 Production Operations The behavior of the system is described (and enforced) by graphical rules called Production Operations Incoming Goods Management: a new truck deliveries raw materials to the factory

13 Automation and Drives Manufacturing Execution Systems Simatic IT Manufacturing Execution Systems SIMATIC IT © Siemens A&D AS MES13 ISA defines Production Operations Production data collection Production execution Production resource management Production dispatching Production tracking Production performance Detailed production scheduling Production schedule Product definition management Level 2 Process Control Production Performance analysis Production capability Product definition

14 Automation and Drives Manufacturing Execution Systems Simatic IT Manufacturing Execution Systems SIMATIC IT © Siemens A&D AS MES14 PRIMARY SECONDARY The result is a Wall-to-Wall Solution Batch E E Orders Mgr Material Mgr Historian KPI Unilab Interspec 3 rd Party SIMATIC IT Services SIMATIC IT Framework Simatic PCS7 Simatic PCS7 Simatic S7 Simatic S7 Simatic WinCC Simatic WinCC 3 rd Party products 3 rd Party products 3 rd Party products 3 rd Party products

15 A&D AS MES Production Suite & Components

16 Automation and Drives Manufacturing Execution Systems Simatic IT Manufacturing Execution Systems SIMATIC IT © Siemens A&D AS MES16 Drag & Drop SIMATIC ® IT Framework is used to model the plant using the Industry specific Library SIMATIC ® IT Production Suite at work Method s & Events Parameters SIMATIC ® IT Components deliver the required functionalities SIMATIC ® IT Framework Coordinates and controls the behavior of the plant Production Operation

17 Automation and Drives Manufacturing Execution Systems Simatic IT Manufacturing Execution Systems SIMATIC IT © Siemens A&D AS MES17 SIMATIC IT Framework - development S95-Compliant Plant modeling Uniform and standard hierarchical organization (Site, Area, Cell, Unit) Workflow definition Integration and coordination of MES applications through Production Operations Decoupling of operational procedures from specific software The Framework describes the components’ behaviour: the real software is needed only at runtime, and is delivered through encapsulation Procedure standardization: The Framework’s object oriented environment allows a painless rollout to different Plants, by using classes, sub-classes, and libraries User Interface: Flexibility and effective scalability thanks to a Graphical User Interface for easy modifications of Plant Model and graphical rules

18 Automation and Drives Manufacturing Execution Systems Simatic IT Manufacturing Execution Systems SIMATIC IT © Siemens A&D AS MES M M M The Model a Production Operation 333 M M M M M M SIMATIC IT Framework - runtime Triggering and synchronizing Components’ tasks

19 Automation and Drives Manufacturing Execution Systems Simatic IT Manufacturing Execution Systems SIMATIC IT © Siemens A&D AS MES19 SIMATIC IT Framework - runtime Detailed monitoring of the executing Production Operations

20 Automation and Drives Manufacturing Execution Systems Simatic IT Manufacturing Execution Systems SIMATIC IT © Siemens A&D AS MES20 SIMATIC IT Production Order Manager Want a clear interface to edit, dispatch and monitor orders? Part of Production Suite

21 Automation and Drives Manufacturing Execution Systems Simatic IT Manufacturing Execution Systems SIMATIC IT © Siemens A&D AS MES21 SIMATIC IT Production Order Manager - Functionality Through SIMATIC IT Production Order Manager you will be able to: import Production Orders downloaded from an ERP manually create new Production Orders customize Production Orders through all the specific detailed information required (custom fields) dispatch Production Orders, either manually or automatically constantly monitor their progress status archive data about executed Production Orders Split, sequence, link orders

22 Automation and Drives Manufacturing Execution Systems Simatic IT Manufacturing Execution Systems SIMATIC IT © Siemens A&D AS MES22 XML Order Import

23 Automation and Drives Manufacturing Execution Systems Simatic IT Manufacturing Execution Systems SIMATIC IT © Siemens A&D AS MES23 Batch Execution Want a powerful Batch Management System to process your order?

24 Automation and Drives Manufacturing Execution Systems Simatic IT Manufacturing Execution Systems SIMATIC IT © Siemens A&D AS MES24 Production Modeler S7 SIMATIC Manager & PCS7 S7 / Others Real Time Execution Engine (e.g. WinAC, DataEngine …) OPC / Drivers Process Control Integration SIMATIC BATCH

25 Automation and Drives Manufacturing Execution Systems Simatic IT Manufacturing Execution Systems SIMATIC IT © Siemens A&D AS MES25 SIMATIC IT Messaging Manager Need to inform and question your operations team? Part of Production Suite

26 Automation and Drives Manufacturing Execution Systems Simatic IT Manufacturing Execution Systems SIMATIC IT © Siemens A&D AS MES26 SIMATIC IT Messaging Manager - Functionality SIMATIC IT Messaging Manager allows you to: Configure Templates of messages thanks to the Template Editor Dispatch messages to workstations, thanks to the Server Module, which sends the requests to the Clients on the destination computers See each message and type in any requested data, thanks to the Client Module (named Messaging Manager Display) Have a complete history of all the messages exchanged in the past, with all the data shown and typed by the user on each message

27 Automation and Drives Manufacturing Execution Systems Simatic IT Manufacturing Execution Systems SIMATIC IT © Siemens A&D AS MES27 SIMATIC IT Material Manager Want to Track all materials in your plant and create a detailed product Genealogy? Part of Production Suite

28 Automation and Drives Manufacturing Execution Systems Simatic IT Manufacturing Execution Systems SIMATIC IT © Siemens A&D AS MES28 SIMATIC IT Material Manager: functionality Material tracking: movements, consumptions, transformations, split, merge, Material genealogy: backward, forward Locations management (detailed as needed, inside the Production area) Bill of Materials (automatic rescaling, versions) Material properties How can I use the same product in order to store data about: Oil: Material quality density temperature Fruit Yoghurt: pH Fruit % Best before end date supplier SIMATIC IT MATERIAL MANAGER

29 Automation and Drives Manufacturing Execution Systems Simatic IT Manufacturing Execution Systems SIMATIC IT © Siemens A&D AS MES29 Track / Trace & Genealogy The Bill of Materials is the basis of the product specification and describes the topology of production

30 Automation and Drives Manufacturing Execution Systems Simatic IT Manufacturing Execution Systems SIMATIC IT © Siemens A&D AS MES30 Track / Trace & Genealogy As SIMATIC IT Framework executes production, Material Manager keeps track of material movements and transformations

31 Automation and Drives Manufacturing Execution Systems Simatic IT Manufacturing Execution Systems SIMATIC IT © Siemens A&D AS MES31 SIMATIC IT Production Operation Recorder Need to track all operational activity for compliance and reporting? Part of Production Suite

32 Automation and Drives Manufacturing Execution Systems Simatic IT Manufacturing Execution Systems SIMATIC IT © Siemens A&D AS MES32 SIMATIC IT Personnel Manager Define and control personnel requirements? Part of Production Suite

33 Automation and Drives Manufacturing Execution Systems Simatic IT Manufacturing Execution Systems SIMATIC IT © Siemens A&D AS MES33 SIMATIC IT Personnel Manager SIMATIC IT Personnel Manager is a component for defining and managing persons at production level. Personnel Manager allows to define groups of persons and single persons, and to customize both by means of properties. Work schedules can be defined and associated to different groups. During the production the presence of persons can be mandatory for achieving some production steps. The integration between Production Modeler and Personnel Manager provides the capability to check this presence. The working times of each person will be collected at runtime: additional data may be associated, such as the Equipment, the OrderID and the LotID.

34 Automation and Drives Manufacturing Execution Systems Simatic IT Manufacturing Execution Systems SIMATIC IT © Siemens A&D AS MES34 SIMATIC IT Report Manager Report on all production activity?

35 Automation and Drives Manufacturing Execution Systems Simatic IT Manufacturing Execution Systems SIMATIC IT © Siemens A&D AS MES35 SAP integration Want to download orders from SAP?  Idoc  PP-PIPCS  tRFC  sRFC

36 Automation and Drives Manufacturing Execution Systems Simatic IT Manufacturing Execution Systems SIMATIC IT © Siemens A&D AS MES36 SIMATIC IT Detailed Production Scheduler Need to create a detailed production plan that considers all plant constraints? Optional Component

37 Automation and Drives Manufacturing Execution Systems Simatic IT Manufacturing Execution Systems SIMATIC IT © Siemens A&D AS MES37 Plant Performance Analyzer Need to define, monitor and archive your KPIs? Not part of Production Suite - SIMATIC IT Historian

38 A&D AS MES Thank you! For more information please visit:

39 A&D AS MES Libraries

40 Automation and Drives Manufacturing Execution Systems Simatic IT Manufacturing Execution Systems SIMATIC IT © Siemens A&D AS MES40 Targets Fast Model creation Pre-defined equipment class hierarchy Simplifies analysis and model configuration for non IT expert Common approach to projects Common libraries of functionality Wide set of functionality for food market Knowledge sharing between library users Fast deployment Pre-defined software interfaces Standard (customizable) User interface Standard (customizable) Reports Simulators

41 Automation and Drives Manufacturing Execution Systems Simatic IT Manufacturing Execution Systems SIMATIC IT © Siemens A&D AS MES41 SIMATIC IT at the Corporate Level Corporate users can standardize the way that plants operate and manufacturing problems are resolved Each plant can drive their own machines people and applications to the same Standard Operating Procedures

42 Automation and Drives Manufacturing Execution Systems Simatic IT Manufacturing Execution Systems SIMATIC IT © Siemens A&D AS MES42 Approach Production type independent Primary and Secondary production Manages multiple ‘behaviors’ (i.e. genealogy on sublot / lot) Enables “wall to wall” solution Flexibility to customer requirements Exclusion / inclusion of functionality Special functions can be added with custom business rules (Production Operations) Device independent Physical configuration change doesn’t require business rule modification Virtualisation of devices (PLC,Terminal,Scada…)

43 Automation and Drives Manufacturing Execution Systems Simatic IT Manufacturing Execution Systems SIMATIC IT © Siemens A&D AS MES43 POM Library Structure Component Data Eng. Data Eng. VB Order Mgt Equip Tools Client Framework Component Downtime Genealogy User Mgt OCX +.NET + Report Universes Industry Library (e.g. F&B) Customer Library Site Library Project MM DPS

44 Automation and Drives Manufacturing Execution Systems Simatic IT Manufacturing Execution Systems SIMATIC IT © Siemens A&D AS MES44 Genealogy Management Library Raw materials / intermediate and final product information Predefined Equipment behavior Mixing FIFO / LIFO Batch Mixing with lower band Mixing with component control Stratification Quantity Management Calculated Online Connection management

45 Automation and Drives Manufacturing Execution Systems Simatic IT Manufacturing Execution Systems SIMATIC IT © Siemens A&D AS MES45 Order Management Library Order Preparation Scheduling Materials Parameters Equipment Order Execution Dispatching Propagate dispatch to linked order Propagate dispatch to Sub-order/Entry Download to control level Batch system PLC/DCS Order Monitoring Status management Change status on production events Propagate order status to linked orders Order History

46 Automation and Drives Manufacturing Execution Systems Simatic IT Manufacturing Execution Systems SIMATIC IT © Siemens A&D AS MES46 OEE Management Library Downtime Management Machine events / status registration Real time KPI calculation (Key Performance Indicators) Management of unknown stops Monitoring and reporting

47 Automation and Drives Manufacturing Execution Systems Simatic IT Manufacturing Execution Systems SIMATIC IT © Siemens A&D AS MES47  Each component offers a standard GUI, plus a set of ActiveX controls and a robust interprocess communication mechanism for building custom clients Client Libraries

48 A&D AS MES SIMATIC IT & PCS7

49 Automation and Drives Manufacturing Execution Systems Simatic IT Manufacturing Execution Systems SIMATIC IT © Siemens A&D AS MES49 Library Libraries At every level of the TIA architecture, a class-instance implementation : Increases reusability and reduces engineering effort Allows partners to add value to the product Reactor class Reactor class Reactor 1 Reactor 2 Reactor 3 Classes are stored in libraries

50 Automation and Drives Manufacturing Execution Systems Simatic IT Manufacturing Execution Systems SIMATIC IT © Siemens A&D AS MES50 S7 Project Library PCS7 SFC Type PCS7 SFC Type Batch Unit Operation The Technical Hierarchy is the heart of the S7 Project Library Reactor WinCC Faceplate WinCC Faceplate

51 Automation and Drives Manufacturing Execution Systems Simatic IT Manufacturing Execution Systems SIMATIC IT © Siemens A&D AS MES51 Unit SIMATIC IT Production Management Objects R101 M102 LT113 M104 FT105 FCV105 TCV107 TT107 SOV205 SOV305 D301 D201 WT302 WT202  Methods  Events  Attributes  Availability  Temperature  Level  Charge  Discharge  Maintain  Get Sample  High Temperature  Downtime

52 Automation and Drives Manufacturing Execution Systems Simatic IT Manufacturing Execution Systems SIMATIC IT © Siemens A&D AS MES52 SIMATIC IT Library SIMATIC IT adds a description of Production Resources to the Reactor Unit SIMATIC IT CORe SIMATIC IT CORe Materials, Personnel, Orders, KPIs Attributes, Methods, Events Rules

53 Automation and Drives Manufacturing Execution Systems Simatic IT Manufacturing Execution Systems SIMATIC IT © Siemens A&D AS MES53 ISA Standards coverage S88 standard Control Module Equipment Module Process Cell Unit PCS7 Project Control Module Equipment Module Process Cell Unit PCS7 Project 2 Control Module Equipment Module Process Cell Unit PCS7 Project 3 Site Enterprise Area S95 Standard SIMATIC IT Production Model Process Cell Unit Process Cell Unit Process Cell Unit

54 Automation and Drives Manufacturing Execution Systems Simatic IT Manufacturing Execution Systems SIMATIC IT © Siemens A&D AS MES54 ISA Standards coverage S88 standard Control Module Equipment Module Process Cell Unit PCS7 Project Site Enterprise Area S95 Standard SIMATIC IT Production Model Process Cell Unit Continuous Discrete Production Unit Work Cell Work Station Production machinery outside scope of the standard C.B.A

55 A&D AS MES Thank you!


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