MES Operations

Industrial automation systems are capable of long hours of operation on their own, but someone must tell it exactly what to make and where, when and how to make it. Plant manufacturing strategy defines this; plant supervisors and operators execute it; and MES software synchronizes every step of the way; giving them the power to control operations, performance and quality.

What is it?

Bring order to just about any industrial operation – from localized production cells to full-scale enterprise integration. Replace disparate applications or manual methods with a single, easy-to-use work order execution engine. Your teams can access job schedules, bills of materials, product specifications, work instructions, inventory utilization, product genealogy, material traceability, and all other key production elements – in action, in consort and in context.

Manage work order execution, enforce products build to specification and capture all execution detail and material flow information in real time on the shop floor.

Such coordination can increase efficiencies, reduce errors, improves quality and increase product yields dramatically. Inventory turns faster, production lead times shrink, new products get to market faster, and much else.

Wonderware MES Operations

Unique execution and data collection capabilities on automated plant equipment make Wonderware MES solutions the first choice for automated or fast moving goods manufacturing processes.

Integrate

Integrate flow of information between shop-floor and business operations.

Optimize

Optimize work orders and priorities for execution.

Standardize

Standardize best practices and operational processes across multiple plants.

Get operations in hand

Improve productivity through faster inventory turns, reduced production lead times and swifter new product introductions – for faster return on investment and enhanced customer satisfaction.

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Integrate

Achieve increased manufacturing supply chain efficiency and business agility through reliable and optimized information flow between shop floor operations and business operations. Automatic downloading and execution of the production schedule as well as finished production and scrap are recorded against each order, shift and plant equipment, and can be made available to everybody in the organization.

Execute

Manage local dispatching of production work orders to lines and machines according to available capacity. Shop floor operators have instant visibility of any schedule changes and can execute production orders according to a timely plan and order. Manage master data for manufacturing operations such as processes, recipes, bills-of-material and quality specifications. Reduce lead times by delivering appropriate process information (work instructions, process and equipment setup specifications) to operators and automated equipment.

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Optimize

Increase real-time visibility of work orders and priorities for optimal execution. Improve predictability of order fulfillment by accurately monitoring ‘planned vs. actual’ production dates and production quantities. Improve inventory velocity through increased visibility into actual material consumptions and inventory movements in real time. Reduce variance in production results by controlling and monitoring operational activities through standardized production methods, procedures and specifications.

Comply

Generate electronic records of operational execution, including detailed information necessary to document finished products production, including product genealogy, traceability of materials, production sign-offs, and labor certifications to provide compliance and governance to internal or external regulatory bodies.

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Standardize

Identify best practices and unify operational processes across multiple plants; standardize ERP integration and shop floor integration with the adaptability to local needs, using a scalable, flexible Manufacturing IT platform.

Scale

Scale the following features for any project:

  • Bill of Material (BOM) Definition
  • Production Management & WIP Execution
  • Production Event Tracking
  • Inventory and Storage Management
  • Procedural Steps, Work Instructions & Document Management
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Why Automate Operations?

With reliable, real-time production information, managers and operators are better equipped to streamline order flow and production execution; track the transformation of products from raw materials through finished goods; and evaluate yield, quality, resource utilization and asset management.

Management

  • Reduced production costs by optimizing product runs and work schedules with less changeover time
  • Improved profitability by increasing throughput, reducing scrap and rework and providing higher quality products
  • Secured brand equity with fast and effective responses to unforeseen events or product quarantine/recalls
  • Increased customer satisfaction by increasing transparency in order fulfillment, effective quality documentation and reducing variance in products built to customer specifications/orders

Operations Teams

  • Reduced production order lead time for rapid responses to changes in demand by dynamic allocation of production assets and more granular production planning
  • Improved inventory velocity through increased visibility into actual material consumptions, movements and inventory levels
  • Improved predictability of order fulfillment by monitoring accurate ‘planned vs. actual’ production quantities
  • Reduced time-to-volume for new product introductions with quick ‘change-overs’ between products and lines
  • Lower variance in production results by improved consistency in operational activities
  • Improved compliance and governance through complete electronic system records for ‘as planned’ and ‘as built’ information
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Track & Trace – Go Deep

Gain real-time visibility into the full range of production processes, from production planning and setup to actual execution of operational activities, as defined by the process model. Production managers and planners can build and view material specifications and grades, bills of materials, manufacturing procedures or steps; define production routing; define shifts; and adopt downloaded production schedules received from the ERP or scheduling system.

During production, track real-time and historical material and labor consumption, lots, WIP inventory, waste, yield and finished good totals, along with other important production events. Build a complete genealogy tree for all production activities. Be prepared to manage product recalls or troubleshoot production emergencies. Such deep visibility to all production information frees you to focus on operating your manufacturing facility with maximum efficiency and productivity.

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Production Agility

The ability to capitalize on fast-breaking opportunities is critical in today’s volatile markets. This requires knowing exactly what is happening in your facility, what is planned, and most importantly what can happen. Put real-time production information at the fingertips of the people who need it most. So your manufacturing teams have the hard data they need to can understand your true capabilities, maximizing improvements, flexibility and responsiveness, to change product runs or lines on demand.

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Consistent Processes and Products

Keeping production runs consistent is key to operational effectiveness. It starts with getting everyone on the same page with the established operating guidelines and procedures. It continues with ensuring that every sees the same bill of materials and material specifications. And is supported by effective team building, detailing user roles, and making sure they are filled with the right people with the right privileges.

Electronic workflow management provides integration of people and systems into operational processes and enforces consistency in operating procedure execution. Workflows can be triggered from planned or unplanned production events to provide notifications and information to the right people requiring a response or decision making feedback as defined in the process specification and business rules. Digitalization of people-based processes provides faster response, increased operational efficiency and mitigation of risks related to manual activities and data entry jobs.

Combining Wonderware MES and advanced workflow software capabilities offers a “Model-driven,” process-centric approach to sustainable enterprise standardization for Manufacturing Operations Management. A unique modeling and engineering environments it easy to adapt templates to address emerging business opportunities and challenges as well as lower risks and effort in creating enhancements, or adapting to individual site needs.

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Best Practices Made Better

Timely and detailed production information enables production teams to measure line performance and refine to perfection. Armed with this information, plant managers can guide their team towards more productive, best operating practices to drive higher levels of plant performance.

Managers and engineers can view and compare the production processes used across their plant or across sister plants to determine which combination of materials, labor, equipment and procedures deliver the best results. Goodbye guesswork; hello streamlined operations.

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Scale with Confidence

What may start as traceability solution or performance tracking can grow in functional capabilities as your requirements evolve. This expanded use increases your return of investment over time and limits project risks and budget with a reasonable step by step implementation.

Optional Modules include:

  • Bill of Material (BOM) Definition
  • Set Up Parameter Management
  • Inventory and Storage Management
  • Procedural Steps, Work Instructions & Document Management

Available Extensions include:

  • In-Line Quality management and SPC
  • OEE monitoring and Asset Utilization tracking
  • Business Process and advanced Workflow Management
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Collaboration On and Off the Cloud

When everyone in the plant has ready access to production information, everything works better. A wide variety of reporting tools help deliver real-time reporting on production events via intuitive user interface screens – on the desktop or in the cloud – so web-based production reports are available to anyone with Internet access and a need to know.