sistemas mes: una visión estratégica - tv.uvigo.es€¦ · the concept of manufacturing execution...
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Sistemas MES: Una visión estratégica
Nicolás PerellóResponsable Comercial División ICAP
GTDOctubre 2007
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Una reflexión para empezar
¡En la nueva economía, la información sobre los activos es más valiosa que los activos mismos!
Geoffrey Moore, Living on the Fault Line
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AGENDA
1. Introducción2. Presentación de GTD3. La importancia del concepto MES4. La definición de MES5. Aspectos claves en las empresas6. La visión estratégica de la solución7. Beneficios de un sistema MES8. Una solución MES9. Un ejemplo real
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Introducción
Visión estratégica de los sistemas MESComprender un sistema MES real
Nuestros objetivos:
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AGENDA
1. Introducción2. Presentación de GTD3. La importancia del concepto MES4. La definición de MES5. Aspectos claves en las empresas6. La visión estratégica de la solución7. Beneficios de un sistema MES8. Una solución MES9. Un ejemplo
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AGENDA
1. Introducción2. Presentación de GTD3. La importancia del concepto MES4. La definición de MES5. Aspectos claves en las empresas6. La visión estratégica de la solución7. Beneficios de un sistema MES8. Una solución MES9. Un ejemplo
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Inversión 2006 vs 2007
5%
3%
15%
21%
9%
11%
39%
4%
12%
22%
10%
14%
34%
3%
Customer Management
Product Lifecycle Management
Sourcing and Procurement
Supply Chain Management
ManufacturingOperationsDesktop software
ERP
Largest Dollar (n=439)Most Important (n=442)
Source: AMR Research 2005 Application Spending Survey
2006: Manufacturing Operations Ranks # 2 15%
15%
8%
14%
19%
7%
12%12%
23%19%
8%
6%6%
10%
Largest Dollar (n=939)Most Important (n=939)
Source: AMR Research 2006 Application Spending Survey
2007: Manufacturing Operations Ranks # 1
Manufacturing Operations is growing:What makes it up????
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Manufacturing Execution
Systems (MES) 22%
Enterprise Asset Management (EAM)
5%
Data Historians 2%
LIMS3%
Product QualityManagement (SPC)
14%
Quality Issue Tracking (CAPA, nonconformance,
Complaints)15%
Advanced Process Control / Simulation
(APC/APS) 12%
Batch Execution 6%
SCADA/HMI3%
Specification & Product Data/ Recipe Management
10%
Enterprise Manufacturing
Intelligence (EMI)8%
Source: AMR Research 2006 Application Spending Survey
Inversión en operaciones de fabricaciónCategorías por % proyectados de inversión en 2007
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AGENDA
1. Introducción2. Presentación de GTD3. La importancia del concepto MES4. La definición de MES5. Aspectos claves en las empresas6. La visión estratégica de la solución7. Beneficios de un sistema MES8. Una solución MES9. Un ejemplo
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La definición de MES
The concept of Manufacturing Execution Systems (MES) was established by Boston-based AMR Research Inc. (www.amrresearch.com) in 1992 as:
The execution layer of manufacturing applications, which exists between the enterprise and control system to provide this visibility and control functionality
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La definición de MES
A later definition came in 1997 from MESA International (www.mesa.org), which stated:
“Manufacturing Execution Systems deliver information that enables the optimization of production activities from order launch to finished goods.”
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La definición de MES
DEFINITION(vendor): A shop floor control system which includes either manual or automatic labor and production reporting as well as on-line inquiries and links to tasks that take place on the production floor. MES includes links to work orders, receipt of goods, shipping, quality control, maintenance, scheduling, and other related tasks.
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La definición de MES
¿Qué aspectos son importantes en una empresa interesada en MES?
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AGENDA
1. Introducción2. Presentación de GTD3. La importancia del concepto MES4. La definición de MES5. Aspectos claves en las empresas6. La visión estratégica de la solución7. Beneficios de un sistema MES8. Una solución MES9. Un ejemplo
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Aspectos clave en las empresas
Mercados dinámicos – => ¡Respuestas flexibles, operativas y de negocio!
Ejemplos– Cambios en el número de referencias– Nuevos tipos de negocio– Tecnologías emergentes como RFID, Internet– …
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QualityIndicators
ERPFinance
AssetAvailability
AssetUtilization
WIP
ROCE
EVA
Activity-BasedCosting
ProductCosting
BalancedScorecards
KPIs
PerformanceBenchmarking
ROI
ROA
CustomerCosting
CIM
Lights-OutSQC
E-Mfg.com
Expert Systems
TQM
6σFieldbus Lean
Mfg
OPC
Internet
EthernetMES SPCERP
Asset Management
CRM
Aspectos clave en las empresas. Sistemas mejora y medida maduros
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Aspectos clave en las empresas
Abaratamiento del Hardware y Software
Necesidad mejora operaciones
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CEO
CFO COO
EnterpriseManagement
ProductionManagement
Plant AssetManagement
Manufacturing Asset Base
Real-Time
Daily
Monthly
Business Measurement Business Operation
Aspectos clave en las empresas. Finanzas lentas de respuesta
FinancialReporting
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Aspectos clave en las empresas (Assets = All Plant Resources, Equipment, Materials, People…)
PrIce
Time
$ ROA
Economic Benefit
Asset Cost
NotMeasured
SometimesMeasured
No easy way to measure economic benefitNo easy way to measure economic benefit
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AGENDA
1. Introducción2. Presentación de GTD3. La importancia del concepto MES4. La definición de MES5. Aspectos claves en las empresas6. La visión estratégica de la solución7. Beneficios de un sistema MES8. Una solución MES9. Un ejemplo
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La visión de la solución. Estrategia versus producto
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Asset Resource MonitoringAsset Resource Monitoring
Product TrackingProduct TrackingProduct IntegrityProduct Integrity
Manufacturing ExecutionManufacturing Execution
Product Definition/ Spec Product Definition/ Spec ManagementManagement
Enterprise Integration Enterprise Integration (ERP/ CMMS, Schedule) (ERP/ CMMS, Schedule)
Quality ManagementQuality Management
Laboratory Resource Laboratory Resource MonitoringMonitoring
Document/ SOP Document/ SOP IntegrationIntegration
Traditional Traditional MESMES
Bringing Production Management/ Operation Management together with Process Management to One Model/ System.
RealReal--time Data Store time Data Store HistorianHistorian
SPC/ Quality Analysis SPC/ Quality Analysis
OEE/ Plant Utilization OEE/ Plant Utilization AnalysisAnalysis
Process Analysis/ Process Analysis/ Alarming and EventsAlarming and Events
Performance Performance / Real/ Real--time time
Time Time AnalysisAnalysis
Supervisory / HMISupervisory / HMI
IntegratedIntegratedProduction & Performance Production & Performance
ManagementManagement
La visión de la solución. Integración total
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La visión de la solución Big bang versus despliegue incremental
Arranque total de una vez
Arranque suave por etapas
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La visión de la solución Evolucionar con los Estándares
Chief ArchitectBoard Director
Board Director
Member
ISA-95 Voting
Member
Board Director
Board Director
Member
Certified
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La visión de la solución Evolucionar con los Estándares. Ejemplo ISA-95
Enterprise InformationPlant Production Scheduling,Operational Management, etc
ManufacturingControl Information
Area Supervision, Production Planning, Reliability, Assurance, etc
ProductDefinition
Information(How to make
a product)
ProductionCapability
Information(What isavailablefor use)
© Copyright 2004 ISA. All rights reserved. Reproduced and distributed with permission of ISA.
Extracted from S95 Part 1 Specification
ProductionInformation
(What to make and the results)
ProductionPerformance
(What wasmade and
used)
ProductionSchedule
(What tomake and
use)
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La visión de la solución Multisectoriales versus especialistas
Generalista Especialista
2
4
6
8
10
12
14
16
18
Sectores
Empresa
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La visión de la solución ROI como barrera
Ejemplo: Modelo “4P” de Toyota
Philosophy: Long term
thinking
Process: Eliminate
waste
People
Problem
solving
Mayoría empresas
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La visión de la solución
Comprobar seriamente la realidad de la oferta de los proveedores
– Todos dicen lo mismo– Olvidarse del nombre del proveedor. Buscar la realidad
– ¡Cuidado con las decisiones políticas!
Ejemplo:– Checklist– Plan estratégico– Plan logístico– Plan sistemas– Participación del equipo– Seriedad– …
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AGENDA
1. Introducción2. Presentación de GTD3. La importancia del concepto MES4. La definición de MES5. Aspectos claves en las empresas6. La visión estratégica de la solución7. Beneficios de un sistema MES8. Una solución MES9. Un ejemplo
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Benefit Benefit Average ReductionAverage ReductionReduces Manufacturing Cycle TimeReduces Manufacturing Cycle Time 45%45%Reduces or Eliminates Data Entry TimeReduces or Eliminates Data Entry Time 75%75%Reduces Work in Process (WIP)Reduces Work in Process (WIP) 17%17%Reduces/Eliminates Paperwork between ShiftsReduces/Eliminates Paperwork between Shifts 56%56%Reduces Lead TimesReduces Lead Times 32%32%Improves Product Quality (Reduces Defects)Improves Product Quality (Reduces Defects) 15%15%Reduces/Eliminates Lost Paperwork/InformationReduces/Eliminates Lost Paperwork/Information 57%57%
Beneficios
Based on the results of a survey conducted by:
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Ejemplos
Reducción de costes
Reutilización de ingeniería
Menor “tiempo a mercado”
Incremento de la productividad
Nuestros clientes dicen…
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AGENDA
1. Introducción2. Presentación de GTD3. La importancia del concepto MES4. La definición de MES5. Aspectos claves en las empresas6. La visión estratégica de la solución7. Beneficios de un sistema MES8. Una solución MES9. Un ejemplo
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Una solución MES
Equipment Operations Module
Equipment Performance Module
Manufacturing Quality Module
Manufacturing Performance Module
Manufacturing Execution Module
Batch Execution Module
Enterprise Integration
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AGENDA
1. Introducción2. Presentación de GTD3. La importancia del concepto MES4. La definición de MES5. Aspectos claves en las empresas6. La visión estratégica de la solución7. Beneficios de un sistema MES8. Una solución MES9. Un ejemplo
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Un ejemplo
Ver película …
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Una reflexión para finalizar
Output gap: Diferencia entre producción actual y la de máxima capacidad
¡En la era del conocimiento, nunca se produce un “output gap”!
Jim Pinto, Pinto’s Points. How to win in the automation business
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¡MUCHAS GRACIAS!