Manufacturing Software

Knowledge . Experience . Commitment

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Document Number: MWare-904-24-02

The information contained in this document is subject to change withoutnotice and does not represent a commitment on the part of PEC Products.PEC Products makes no warranty of any kind with regard to this document,including, but not limited to, the implied warranties of merchantability andfitness for a particular purpose.PEC Products shall not be held liable for errors contained herein or direct,indirect, special, incidental or consequential damages in connection withthe furnishing, performance, or use of this material.

This document is:Copyright © 2005 PEC Products NV. All rights reserved.

PEC, MWare are trademarks of PEC Products NV.

Trademark™ PEC Products NV. All rights reserved.

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Compatibility LevelMWare Version 2.4

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+1 (561) 962.28.24 (The Americas)E-mail: info.mware@pec.be

Technical SupportTelephone: +32 (0) 16 39 83 39 (EMEA – Asia Pacific)

+1 (561) 962.28.24 (The Americas)E-mail: mware.support@pec.be

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Contents

Managing your production! 4

MWare offers all that, and much more 5

MWare's Industry Specific Templates 5

Concepts 6

Controlling your Manufacturing Processes 7

Controlling your Materials and Components 9

Controlling Continuous Improvement 10

Technology 11

Web Services 11

Reporting 11

Enterprise Collaboration 11

Reliability 11

Step-by-Step, Implementation Methodology 12

MWare Products 14

Knowledge, Experience, Commitment 15

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The continuous evolution in manufacturing strategy has radically changedthe way successful manufacturers operate today. Next generationmanufacturing and information systems must address these changes andfocus on new requirements.

These requirements are often lead by new initiatives and strategies, suchas Lean Manufacturing, Six Sigma, and TPM. The implementation of thesestrategies is making the plant more agile and efficient when it comes torunning smaller lot-sizes, reducing lead-time and reacting to changingcustomer demand.

In order to achieve this level of World-Class Manufacturing, manufacturersneed more transparency in their processes and products. They need toolsto capture the required data as well as systems to turn this data into real-time information. This decision-supportive information helps productionmanagers, supervisors, and operators to make the right decision andeliminate costly mistakes before they occur.

MWare can addressthese challengeswith out-of-the-boxsolutions :

. Integrated material and capacityscheduling

. Paperless automation of thedifferent workflows in the factory

. Meeting stronger regulations inTracking and Tracing

. Enforcing quality procedures inthe factory

. Getting grip on your inventoryand Work-In-Progress

. Improving your plant logistics

. Implementing Total ProductiveMaintenance

. Calculating your OverallEquipment Efficiency

. Creating Real time information ofplant activity

Managing your production!

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MWARE OFFERS ALL THAT,AND MUCH MORE

MWare is an object-oriented and component basedManufacturing and Logistics Execution System (MES -LES), designed for discrete and mixed manufacturingprocesses, in a variety of industries.

MWare is completely configurable, delivering theflexibility to grow with the company's needs. MWarecollaborates with other factory automation systems likeERP and Supply Chain Management solutions. Theintegration with LIMS, SCADA, and Process ControlSolutions is realized through open interfaces, whichenable seamless enterprise integration between allbusiness systems.

MWare allows you to capture and distribute allproduction related data throughout your company in real-time, giving everyone in the company, from operators tomanagement, access to the same up-to-dateinformation, presented in a useful way for each specificrole.

MWare records all historical and genealogical data andturns it into performance information needed forresource and quality management, processimprovement and activity-based costing.

MWare includes an extensive APS module, which willsupport both short and mid term capacity and materialcontrol.

Using MWare’s short-term benefits has a positiveimpact on the long-term corporate objectives such asincreased profitability, reduced working capital andimproved global competitiveness.

MWARE'S INDUSTRY SPECIFICTEMPLATES

In order to speed up the implementation of the MEScomponents, MWare includes industry-specificimplementation templates. These templates containpre-configured MES components and support industry-specific functionality.

These pre-configured, business solutions are designedfor manufacturers seeking a fast, tailored MWareimplementation. The combination of optimizedbusiness processes, industry-specific needs, andproven implementation methods guarantee our clientsan adapted comprehensive MWare solution supportingthe best manufacturing practices within the shortestpossible timeframe.

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MWare is comprised of different modules that can beimplemented individually, but always respect theintegrated approach of MWare. Each module covers aspecific functional domain leaving no need to createand maintaine interfaces, as each module shares itsinformation in one common platform.

The different modules are grouped in four maincomponents:- Flow Control: Tracking and Tracing, Planning and

Scheduling, Shop Floor Control, ProductivityTracking

- Quality Control: Inspection Plans, Electronic QualityData Entry Sheets, Process Tracking

- Logistics Control: Logical and Physical Inventory andWarehouse Management, Control of all materialmovements

- Maintenance Control: Operational aspects ofmaintenance management, such as taskgeneration and workflow management

Concepts

The MWare Configuration Manager module is used toconfigure and update the manufacturing model in theMWare system. Business processes and Master Datasuch as machines, work centers, item groups, and userprofiles, can be changed on the fly, withoutprogramming.

The MWare Configuration Manager also allows thecustomization of the standard MWare User Interfaces,in terms of permissions and authentication. This waythe interface can be tuned to the diverse needs that arereflected by operators, supervisors and management.

All these modules collaborate to control and managethe different aspects of production. The integratedworkflow management assures that your businessprocesses, in relation to manufacturing, materials andcomponents, and continuous improvement, are strictlyenforced and automated.

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CONTROLLING YOUR MANUFACTURING PROCESSES

You must be able to change your factory’s schedule to real life situations,such as adjusting to order progress, but also adjusting to the unexpected,such as labor shortages, requirement changes, rush orders, equipmentfailures and material problems.

Therefore the plant must be well integrated with the enterprise level, includingvendors and customers, optimizing its internal operations in the most effectiveway. This complexity can only be resolved with tools that guarantee real-timecoordination between production, inventory, and plant logistics.

Plan the Work and Work the Plan

MWare has integrated Advanced Planning and Scheduling (APS) within theMWare kernel functionality. This results in an optimized plan taking intoaccount the limited capacity of labor, machines, and materials.

The combination of MES with an integrated APS environment will guaranteethat any change coming from the shop floor will have an immediate effect onthe planning. In addition, every change in an enterprise requirement,including its influence on the detailed plan, will be available to the shop floorin real time.

MWare's APS Manager offers all tools for finite and infinite capacity scheduling.Gantt charts, load reports, delivery capability reports give you in depthinformation on the results while a configurable scoreboard offers a fastoverview of all key points of interest.

At shop floor level the up-to-date schedule is available immediately uponrelease. By enforcing the planning, the factory will benefit from an optimizednetwork plan versus a sub-optimized operation sequence at the machinelevel.

MWare will fundamentally improve your competitiveness by increasing costeffectiveness and providing a better service to the market with faster and ontime deliveries.

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Automated Logistics

The scope of the MWare logistics module covers the physical tracking andtracing from the raw materials entering the plant, to Work-In-Process andsemi-finished goods, until the finished goods leave the factory.

By integrating the detailed warehouse management within the MESenvironment, MWare can prepare the material transports in line with theproduction plan. A change in planning also has an immediate effect on thisinternal supply chain process.

The MWare Logistics Execution System automates these processes usingmobile terminals on lift trucks, Automated Guided Vehicles (AGVs), AutomatedStorage and Retrieval Systems (ASRS) or any kind of material handlingdevice. MWare offers standard interfaces to these systems, optimizingallocations of materials, storage locations and material handling systems.

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CONTROLLING YOUR MATERIALS ANDCOMPONENTS

Increasing rules and regulations emphasize theimportance of quality assurance during each step ofthe manufacturing process. Each factory will need todefine a strategy that will increase quality while keepingdirect and indirect costs under control. MWare MES willhelp automate these processes, hence reducing yourcost of quality.

Tracking and Tracing

MWare offers unique functionality for tracking and tracingmaterials and components. This concept is based ona UWIP (Unit of Work In Process). A UWIP is the smallestidentifiable unit on which tracking and tracing is required.

For every manufacturing step a UWIP can have differentformats, with different units of measurement,quantities…. Typically a UWIP is mapped to a pallet, abin, a tray or even the individual serialized work piece.

The UWIP forms the central repository on which alltransactions are validated and archived. UWIPs formthe basis for quality control, lot traceability, hold/releasecontrol, process control and warehouse and locationmanagement.

Traceability can be organized in a time-line conceptand can be extended with a 100% discrete relationbetween ingoing and outgoing materials. The time-lineconcept enables MWare to link every action or event toa single time axis in the plant. This way each materialconsumption, machine breakdown, or process controlevent is correlated to this axis in real time.

Using historic data, the system can track all materialrelations between raw materials, semi-finished andfinished goods. Alternatively the same historic data canbe used to track down a quality problem in a UWIP tothe process parameters at the time of production, or tothe individual who executed the operation!

Elimination of Waste

A fundamental part of the MWare concept is theenforcement of the correct manufacturing procedures,related to process and quality control. The enforcementhelps operators avoid costly mistakes by double-checking all relevant operator activity.

MWare performs real-time integrity checks on qualitystatus of input materials, accuracy of the Bill-Of-Material,and the sequence of operations….

Another method to avoid waste is the enforcement ofquality assurance procedures, such as screening testsor AQL, Statistical Process Control, 100% control, etc...MWare offers tools to configure and execute these tests,and store the captured data for further usage.

Since most of these procedures are dependant on userrights, MWare offers a complete role-basedauthentication system, which allows the systemadministrator to clearly define responsibilities andrestrictions in the system. These roles will beautomatically translated into authentication prompts forthe corresponding actions, which can be signed offusing digital signatures. With this system, MWaresupports regulated industries, and any othermanufacturing plant, in organizing product and processtraceability with detailed audit and trail functionality.

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Total Productive Maintenance (TPM)

The basic goal of the MWare Maintenance Managermodule is to bring the operational side of MaintenanceManagement to the factory floor, supporting differentmaintenance policies and concepts. This may includepredictive, corrective and preventive tasks, triggered ontime or cycle intervals.

With the ever-increasing success of TPM, MWare addssupport for typical operational issues, such as theplanning and execution of maintenance tasks,generating tasks based on alarm situations, etc...

MWare tracks the usage of the different componentswithin a machine and keeps a history of relevantmachine parameters, which allows the MaintenanceManager to update its maintenance schedules. It alsomaintains a history of past events, which speedsup problem diagnosis.

Using these features, MWare contains all informationfor detailed OEE calculations on the machine andcomponent levels.

MWare also provides maintenance-specific interfacesto ERP Systems to retrieve and update information inthe cost-oriented administrative environment.

CONTROLLING CONTINUOUSIMPROVEMENT

In the global economy, market prices are decreasing,thus squeezing margins. This results in a continuousneed for efficiency and quality improvement, increasedthroughput, and detailed cost control.

Factories require real-time information that can bedisplayed from operator to management level, showingtargets, failures and performance in clear,understandable reports. MWare focuses on differentelements in this area, providing real-time informationfor production, maintenance and operationsmanagement.

Performance and Availability

MWare helps you identify reasons for your dailyinefficiencies. Using the events generated by operatorsor process control systems, MWare tracks thedowntimes and reason codes at both the detailed andaggregated level.

A drill-down PARETO analysis guides you to informationthat was invisible before. MWare generates detailedoverviews on plant, department or machine level,showing real-time and historical trends on your KPI'ssuch as Overall Equipment Efficiency (OEE),throughputs, quality ratios, scrap quantities, yield, etc….

Because machine hours and all direct and indirectlabor hours can be monitored, MWare generatesaccurate information for detailed cost controllingsystems at the ERP level.

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WEB SERVICES

MWare is completely built on the Microsoft .NET platform,and supports both SQL Server and Oracle databases.The MWare Application Server exposes all MWaretransactions as customizable web services, allowingany kind of .NET or JAVA client application to use theMWare functionality.

The standard MWare user interfaces are alsocompletely .NET compliant and run as a smart clienton any recent Windows PC platform. With the No-Touch-Deployment capability, the distribution of the clientscreens and applications in the factory is completelyserver-managed.

The client applications can also be deployed on ThinClients and Windows CE-based terminals using MSTerminal Services or Citrix application hostingenvironment.

This results in a lower cost of ownership and a highlymodular, open and flexible solution.

REPORTING

The aim of the reporting services is to provide therequired business and progress reports from yourproduction environment in real-time. The reports includeboth operational and historical information.

In order to facilitate multi-hierarchical analysis, MWarestores all relevant information in the MWare DataWarehouse. The standard MWare grid provides a clearview of this information, with user-specific reportingcapabilities, including filtering, multi-level grouping, andcustomization of the grid columns.

Technology

ENTERPRISE COLLABORATION

In order to synchronize the MWare system with theEnterprise level, the MWare system will generate XMLmessages that can be uploaded to e.g. the ERP system.These messages can be used e.g. to create stockmovements between different ERP stock locations andWIP.

The download of messages is handled via XML whichis in line with worldwide standards, such as ISA95.They can easily be customized to your specific needsand interface requirements.

RELIABILITY

MWare is designed to support ‘24/7 days' manufacturingoperations. This is obtained by using clustereddatabase and application servers and high availabilityon the network level.

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In order to achieve a successful MWare implementation, PEC created amethodology that allows deployment of our MES solution in months insteadof years. By leveraging the best business practices gathered over years ofimplementation experience, PEC developed the Step-by-Step. This resultsin a rapid implementation model with proven success and the quickestreturn on the MWare investment.

Step-by-Step provides a phased implementation path with clear milestonesand deliverables after each stage. This helps PEC clearly analyze and designMWare in every customer-specific situation, allowing the customer toaccurately determine the cost and timing of your MWare implementation.

Step-by-Step equips you with the essentials for success: the process, tools,training and services. Step-by-Step is based on the Unified ModelingLanguage methodology, which is a worldwide standard in softwaredevelopment and implementation.

The starting point for every implementation is completely process-based,and can be used to capture and re-engineer your existing manufacturing,quality, planning and logistics business processes.

Step-by-Step lays a solid technology foundation for continuous businessimprovement and for future MWare upgrades.

Step-by-Step uses a 4-phase implementation cycle. All phases are clearlydefined, and allow the project team to closely track progress made:

INCEPTION PHASE

Every successful project starts with a preparation phase, in which objectives,resources and priorities are defined. In many cases this phase is used tocreate the awareness within all levels of the manufacturing plant, to capturethe functional specifications and to finalize the project scope.

During this phase, the feasibility of the MWare implementation is checkedwith the real-world situation.

The Inception Phase is documented in a pre-study report, on which furthercommitments can be applied to budgets and timing.

Step-by-StepImplementation Methodology

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ELABORATION PHASE

During this second phase, the MWare consultant performs a detailed analysisand design of the manufacturing processes, including the setup of a prototypeimplementation. This establishes a baseline architecture for the MWarecustomization and implementation. It also provides your project team clearcontrol of the implementation scope and to focus only on the MWareprocesses needed to run your plant.

The architecture includes a detailed description of the organizational unitsand master data, such as Work Centers, routings, BOMs, reason codes,etc…

Furthermore, the integration aspects with ERP, APS, SCADA, SPC and othersystems is covered in this phase.

The result of this second phase is a fully elaborated model, creating a detailedplan for the construction phase.

CONSTRUCTION PHASE

During the Construction Phase the consultants build and test a workingsystem iteratively according to the previously elaborated plans. First theproject team configures the baseline architecture, using the ConfigurationManager module.

Secondly, the project team fine-tunes the system to meet all your businessand process requirements. The second phase may include specific softwaredevelopment, which uses the available MWare interface components.

TRANSITION PHASE

Final preparation takes your system through rigorous testing and your endusers through comprehensive training. This guarantees a smooth transitiontowards the new platform.

The transition phase is not the end of the MWare implementation but thebasis for continuous improvement in the manufacturing plant.

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MWare Products

MWare is designed to grow with the company's needsand requirements. This covers both functional needsand size. Since MWare is designed on a multi-tierenvironment, allowing a step-by-step extension, thesystem will guarantee the investment protection youneed.

MWare is available with the following servers andoptional components:· MWare Application and Database Server· MWare Report Server. MWare Relocation Manager (optional component)

MWare Maintenance Manager (optional component)MWare APS Manager (optional component)

· MWare Operator InterfaceMWare Supervisor Interface

MWare Application and Database Server

This module is the heart of the system and can beinstalled on any Windows 2003 compatible serverplatform. It contains both the database server programsand the business logic. Since MWare is a .NETapplication, the application server uses the MicrosoftInternet Information Server platform for the exposure ofthe web services to the client applications.

The clustered server platform will also run the databaseserver, which can be Oracle or Microsoft SQL Server.

MWare Report Server

This module is installed to distribute both operationaland historical data via the standard MWare UserInterface. This way every authorized network user, localor remote can consult the same data on a singleplatform.

The module can be installed as a separate applicationserver, running the different reporting services, includingthe Data Warehouse.

MWare Planning and Scheduling

MWare Planning and Scheduling is a complete solutionfor finite capacity scheduling. Its macro-based planningfeatures allow you to automate common tasks, savingtime to deal with the exceptions. The planner provideswith extensive simulation and visualization tools in orderto make decisions based on fact.

MWare Operator Interface

The MWare operator interface is a smart-client userinterface for the shop floor. It is designed to facilitateoperators in their day-to-day transactions, using touch-screen compliant grids and buttons. The standardoperator interface requires a PC environment, runningany current Windows platform.

Screens are customizable through parameterizationand can therefore be tuned to the customer needs. Thismay even include running the screens from a PocketPC environment, with a reduced screen footprint.

The operator screens are Machine-centric, giving theoperators a clear focus to the activity required at theirworkstation.

MWare Supervisor Interface

The MWare supervisor screens offer more in-depthfunctionality for supervisors and management,including online production overviews, supervisoroverruling, reporting screens, etc... From its userinterface the supervisor can monitor in detail the actionsperformed on the shop floor.

PEC, established in 1984, is an international groupproviding the latest manufacturing technology to a widerange of market leading companies in differentindustries.

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Knowledge, Experience,Commitment

KNOWLEDGE

Our company is staffed with industry experts in manufacturing relatedtechnological and functional domains, such as manufacturing engineering,equipment control, quality assurance, logistics, inventory management,planning, scheduling and maintenance.

Our strategy is based on the development of standard building blocks suchas MWare, in combination with implementation services from PEC or fromour certified implementation partners.

We are able to embrace your manufacturing needs in a fully integrated way;from the industrial equipment level to a plant-wide MES/LES implementation.

EXPERIENCE

Leveraging the best business practices gathered over years ofimplementation experience and combining them with our technological skillshas evolved in a rapid implementation model with proven success.

For certain industries PEC has started centers of excellence, bringing togetherthe experience and best practices for that industry. This has created thepossibility to implement the most advanced automated system in a minimumtimeframe.

COMMITMENT

Our long track record of successfully completed projects forms a solidfoundation and gives you the best guarantee for a fast return on yourinvestment.

PEC takes full commitment from the initial consulting stage to the on-siteinstallation, training, global support and maintenance of the system.

PEC is headquartered in Belgium, Europe with direct operations in CentralEurope, the Americas and Asia Pacific.

PEC is committed to further develop its international support base directlyand in combination with its global implementation partners.

PEC HQ

Technologielaan 12B- 3001 Leuven, BelgiumTelephone: +32(0)16 39 83 39Fax : +32(0)16 39 83 69

PEC Central Europe

Lanchid u. 23 VIIH-1013 Budapest, HungaryTelephone: +36 1 487 70 10Fax: +36 1 487 70 11

PEC North America

2385 NW Executive Center DriveSuite 100Boca Raton FL,33431 USATelephone : +1 (561) 962 2824