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© Brückner1/ 20
Manufacturing Execution Manufacturing Execution SystemsSystems
Achieving high efficiency and traceability in Achieving high efficiency and traceability in film manufacturingfilm manufacturing
Wolfgang ZintzWolfgang ZintzBrBrüückner ckner ServtecServtec GmbHGmbH
© Brückner2/ 20
Manufacturing Execution Systems
Highlights
Definition
How to Measure
How to Improve
What You Get
© Brückner3/ 20
Highlights
Maximise Throughput
Gain Flexibility (Production Control)
Reduce Stock
Reduce Maintenance Cost
Guarantee Traceability
© Brückner4/ 20
Manufacturing Execution Systems
Highlights
Definition
How to Measure
How to Improve
What You Get
© Brückner5/ 20
What is MES?
Manufacturing Management System MMS
ISA Level
4
3
2
1
0
© Brückner6/ 20
MMS Integration
Entire ProductionProcess
Multiple Sites
Various Suppliers
© Brückner7/ 20
Existing Solutions
Paper Interface?
Standalone Systems?
Integrated Solution?
© Brückner8/ 20
Existing Solutions
NewStandard
© Brückner9/ 20
Manufacturing Management Systems
Highlights
Definition
How to Measure
How to Improve
What You Get
© Brückner10/ 20
How to Measure
Online Data (Process)●Real Time
●Long Term
●Roll Related
●One System
Offline Data (Lab) ●Mill Rolls/Slit Rolls
●Specification Check
© Brückner11/ 20
Tracking & Analysis
Raw Material Balances
KPI in Real Time(Key Performance Indicator)
… all per mouse click !
How to Measure
Data Information Best Decision
3%1%
96%
Production Startup Filmbreak
© Brückner12/ 20
Key Performance Indicators
Production Time [h]Availability = Total Time [h]
UnplannedDowntime
PlannedDowntime
SetupTime
Total Time [h]
Production Time [h]
Actual Throughput [kg/h] Performance = Nominal Throughput [kg/h]
Process & MachineProblemsActual Throughput [kg/h]
Nominal Throughput [kg/h]
Good Film [kg]Quality =Material Consumption [kg]
Edge TrimYield
Material Consumption [kg]
Good Film [kg]B-GradeRejects
Overall Equipment Effectiveness OEE= A x P x Q [%]
© Brückner13/ 20
OEE Example
TypicalResults
95%
95%
93 %Production Time [h]Availability =Total Time [h]
Actual Throughput [kg/h] Performance =Nominal Throughput [kg/h]
Good Film [kg]Quality =Material Consumption [kg]
OEE [%] = 93 x 95 x 95 = 83,9%
© Brückner14/ 20
Manufacturing Management Systems
Highlights
Definition
How to Measure
How to Improve
What You Get
© Brückner15/ 20
How to Improve
Planning and Scheduling
CUT Optimisation
Maintenance System
MMS = Flexibility, ThroughputLess Stock, Delivery Time
… all per mouse click !
© Brückner16/ 20
Manufacturing Management Systems
Highlights
Definition
How to Measure
How to Improve
What You Get
© Brückner17/ 20
What You Get
“Total Integration”
Next Level Technology
Focus change Operative Strategic
© Brückner18/ 20
What You Get
You Save ●Set-up time●Change-over waste● InventoryYou Improve●Product to market timeYou Gain● Increased market share
© Brückner19/ 20
Manufacturing Management Systems
“The only constant in the universe is change”
Thank You!