Transcript The Role of Manufacturing Execution Systems and Their

THE ROLE OF MANUFACTURING
EXECUTION SYSTEMS AND THEIR
EFFECT ON QUALITY IN
MANUFACTURING
Christian Zrilanka
ASQ Presentation
Central North Carolina Section
Manufacturing Execution Systems (MES)
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MES is a top-level manufacturing control system.
MES is comprised of computer servers and a
Structured Query Language (SQL) database.
The MES communicates with Programmable Logic
Controllers (PLC’s) and SCADA (Supervisory Control
and Data Acquisition) systems.
The MES is a key component to an organization’s
Enterprise Resource Planning (ERP) system.
MES Benefits
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MES systems, by definition, bring an entire process
under control.
Gives an organization “vision” into a process.
Provides an approved means of data collection by
governing bodies.
Provides unlimited possibilities for quality control
and/or monitoring.
Current Manufacturing Data Acquisition
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Data can be manually obtained.
Data can be manually retrieved from PLC memory,
analyzed, and counted.
Data can be manually retrieved from SCADA
systems, analyzed, and counted.
Data can be manually retrieved after a
manufacturing process has been completed by
analyzing final product.
MES Manufacturing Data Acquisition
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Data can still be manually obtained, as needed.
Data is automatically retrieved from PLC memory
and saved in SQL database.
Data is automatically retrieved from SCADA
systems and saved in SQL database.
Data is automatically retrieved after a
manufacturing process has been completed by
analyzing final product and storing findings in SQL
database.
Quality Functions Within A MES System
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Quality processes are divided into two categories
within the MES:
 Control
of those systems that have built-in Statistical
Process Control (SPC)
 Actual control of those processes that are governed by
Statistical Quality Control (SQC) processes
SPC Controlled Processes
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Processes controlled by SPC systems will continue to
be “locally” controlled by those systems.
SPC systems are monitored by MES systems with
supervisory controls
Alarms, Key Performance Indicators (KPI’s), and
other parameters are stored and monitored by
MES.
SQC Controlled Processes
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Processes controlled by SQC systems will fall under
direct control of MES system.
SQC systems are monitored by MES supervisory
controls.
Alarms, KPI’s and other parameters are stored and
monitored by MES by separate MES “dashboard”
programs.
MES and Quality
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MES systems provides “data at your fingertips” for use in control
charts and other quality functions.
Data can easily be imported into other programs—such as Microsoft
Excel—for further representation and analysis of data.
MES systems provide real-time quality control data that keep
processes in control.
MES stores data in approved manner by governing bodies.
Allows organization to “visualize” processes.
Allows organization to be proactive rather than reactive.
Reduces human intervention errors for more accurate quality control
information.