Changing MES platform within 4 months - MESA · PDF filePAS files to Loftware) • Test machines were connected to SCE sending there results and failure diagnosis, parametric data

Copyright 2011 MESA North American Conference

Changing MES platform within 4 months

Martin HubeňákIT Manager

Tyco Fire Protection Products


Agenda

• TFPP Ráječko Site Introduction• Project Description• Original MES system• Documentation and process review• Process definition and modeling in new MES system• Implementation and migration activities• Project summary


TFPP Ráječko Site introduction Ráječko located in Czech Republic, Central Europe

Manufacturing portfolio: PCBAs, Fire detectors, Call points, Nurse call, Smoke detectors

Over 1 100 product PNs Volume approx. 1.7 mil units/year Site space: total 17,000 sqm (183,000

sq ft) Employees 320 Years of service: 7,6 24/5 regime, 3 shifts

Ráječko


Project description

• Replacing existing Shop Floor Control System• Replacing existing supporting applications like Shop Floor Reporting Label Printing Tester interface application

Project task


Project description

• New flexible system applicable in various types of productions

• Opportunity to review and standardize current processes

• Support new quality and process standards• Open the system for integration with other systems like ERP

and PDM

• Minimize the using of customized activities

Benefits


Project description

• Aggressive timeline 4 months for implementation

• Implementation of ERP, MES and PDM systems in parallel

• Needed resources shared with other projects

Risks


Assumptions

• Evaluate the benefits of MES system.

• Separate task “MES cost justification” with result YES.• Quality, Operations, IT, SCM, FIN teams needed 3 months

to evaluate the MES project implementation.

• Decision regarding strategic MES platform for future.

MES system yes or no?


Assumptions

• Adaptable platforms for various types of manufacturing processes

• Easy to identify and implement basic modules with option to extend the functionality in future.

• key to success - Reducing the requirements for end user training – systems can be designed to meet current valid work instructions.

• Flexibility for Global Operations

Opportunities during implementation of new MES platform


AssumptionsExample of Tyco MES Operator Interface


Assumptions

• key to success - Needed HW architecture prepared on time.• Decision regarding placement of application and database

servers – on site.• Decision regarding database platform and OS - Microsoft

against UNIX and Oracle used in former MES platform.• Implement solution for support applications like Label

Printing and interface with the test machines.

Hardware and Support applications


Assumptions

• key to success - Creating skilled team is essential condition for successful result of the project

• Adequate sources on partner side

Competent team


Assumptions

Tyco team:Project manager IT MES Project leaderOperations manager IT managerMES shop floor administrators Quality manager IT Developer ProgrammerQuality engineers Process engineersTest engineers ERP consultantPDM super user IT MES analyst

Competent team


Project Scope• Manufacturing flow at shop floor Modeling of routers/processes Starting from order creation and release Ending at packing of finished goods

• Finished goods WIP inventory management Declaration at the end of production line Counting of finished goods stock Real-time visibility


Project ScopePreparation

Assembly

Inspection

Test

Packing

Manual

Repair

Serial Number Release, Label Printing, Component Validation

SMT (Surface mounting), component trace

Component trace, product configuration

Quality control

Automated test

Alternative flow

DebugRepairDisassemblyScrap

Multilevel packingLabeling


Project Scope

• Semi-finished goods WIP inventory management Counting Visibility

• Two way communication with test machines

• One way communication with line scanners

• Two way integration with ERP system

• Reporting


Project Scope

• Quality management Ad-hoc quality data sampling Basic quality sampling planning Ability to hold/release entities

• Contextual work instruction visibility


Systems architecture, original status

Label Printing app.

Reporting app.

Data Warehouse

Tester Interface app.

ERPDB PDMDB

MESDB


Systems architecture, current status

Reporting app. Tester Interface app.

ERPDB PDMDB

MESDB


Original MES system

• Site’s former MES system was SCE 3.0.1.1. Data stored in Oracle 9i.

• Loftware was used as printing solution (MES system sending PAS files to Loftware)

• Test machines were connected to SCE sending there results and failure diagnosis, parametric data and/or SLIP files


Original MES system

• Data were pulled from MES database to Data Warehouse (DW) in 30mins cycles. Oracle Report and Oracle Discoverer tools were used for reports‘ design.

• Note: SCE was used for many years, was very well tuned and customized to fully support business requirements for product tracking and quality outputs. Consumed components as well as finished goods were automatically backflushed into ERP system.


Project schedulePhase / Task / Milestone ScheduleProject Kick Off – Planning and Prep 23/08-29/08Blueprint & Realization Iteration 1 30/08-03/10Blueprint & Realization Iteration 2 04/10-24/10Blueprint & Realization Iteration 3 25/10-14/11Blueprint & Realization Iteration 4 15/11-05/12Conference Room Pilot 15/11-28/11Final Preparation (Deployment) 13/12-23/12Go Live and Stabilization 03/01/2010Project Completion and Transition to Support

03/01-17/01


Documentation and processes review

• key to success - All production processes were carefully documented

• Benefit - almost no process changes identified (processes constantly improved in the past)

• Due to very short time for new system implementation it would not be reasonable to proceed with major changes at the same time.


Documentation and processes review• Example of document which describes Pack functionality


Process definition and modeling in new MES platform

• Partner consultants were modeling and accommodating MES system based on their methodology and our requirements in four iteration steps (4 weeks each).

• Each step started with definition of the processes involved in the step and ended with user acceptance tests.


Process definition and modeling in new MES system

• At the end of fourth iteration all essential features/functionalities were available (serial number tracking, component traceability, backflush of consumed components into ERP system and so on).

• Rest of processes identified as non-critical (like RMA support, Change production, Time-Based Traceability) were implemented after go-live.


Process definition and modeling in MES


Processed definition and modeling in MES


Implementation, partial go-live

• First implementation step, partial go-live• Build few identified PNs in new MES in the mid of December• key to success - experience with the new product on the

shop floor• Demonstrate, that the system is ready to support at least

most critical production phases• Rest of production was still traced in former MES system


Implementation, Production Data Migration

• Production master data like process flows, products definitions, BOMs needed to be set in MES.

• Two options to set product data used Manually due to complexity key to success - migrated using various developed scripts

to pull the data from former MES’s underlying Oracle 9i and send them into new MES’s MS SQL 2008


• key to success - without such automation of data migration we would not be able to set all needed data as there are hundreds of products and product revisions being build

Implementation, Production Data Migration


Implementation, Cut Over

• Cut Over – production stop, week between Christmas and New Year

• key to success - Cut Over plan – coordination with ERP project

• Physical Inventory required• Testing interface between new ERP and new MES systems• Testing interface with line testers/machines• Set and test all production Zebra printers


Implementation, Cut Over

• key to success – WIP transfer• Programs in VBA code needed all unfinished SNs in existing MES introduced into new

MES system after that moved to the correct position in their process

flow• SNs with open non-conformances were placed in queue for

the test operation they failed so by retesting them we got the NC data into MES and had no missing data.


Label printing

• Zebra printers used

• Variety of label layouts is small• Decision not to use any label printing

software but to use Zebra’s ZPL code and just replace parameters with real values before sending ZPL to the printer.


Label printing

• Currently there are about 25 different label designs and 15 Zebra printers on the Shop Floor (mainly supporting PACK operation).


Tester Interface

• There are various test machines like incircuit testers, functional testers, optical inspection machines.

• There are many various applications and operating systems (old versions of Windows but also HP Unix).

• key to success - New interface application developed in Java enabled all test machines connection with MES without any change on tester side.


Tester Interface• The interface application was essential as there was not

enough time and resources to do the change for each test machine.


Reports• Various production and quality reports have been developed

in MS Reporting Services.


Summary

Go-live started on January 3rd when all production started to be traced in new MES system.

Meet the deadline Meet the budget Stable system, no outage from Go-live date (9 months) Excellent Production and Quality KPI’s – MES system

justified


Summary, MES justification

• Quality First Pass Yield – 96% DPPM – 0

• Costs Productivity (working hours utilization) – 100 % CC (# of customer complaints) – 0

• Delivery OTD-R (on time delivery based on 1st commit) – 97%


Key to success, assumptions

• No requirements for end user training – applicable MES platform

• Needed HW on time• Motivated competent team, project management• Documented processes• Programmer, database specialist• Excellent team on partner side – Thank You

Is it possible to replace MES system within 4 months?YES, in case that:


Thank You

Documents

Changing MES platform within 4 months - MESA · PDF filePAS files to Loftware) • Test machines were connected to SCE sending there results and failure diagnosis, parametric data