MES Implementation in a Defense Industry Company CON2874 30.09.2014

MES Implementation in a Defense Industry Company CON2874

30.09.2014

MES Implementation in Roketsan

Ferruh Emre AytacMES Project ManagerUnit HeadProduction Planning Dept.

Efe Can OkumusMES Project CoordinatorEngineerProduction Planning Dept.

Table of Content

1. About Roketsan

2. Oracle Footprint at Roketsan

3. Purpose and Scope of MES Project

4. Challenges in Implementation

5. Developed Applications

6. Project Calendar

7. Project Facts and Achievements

8. Future Projects

3

General Information

About Roketsan

4

General Information

• Founded in 1988

• One of the Leading Defense Industry Firms in Turkey

• Specialized in Designing and Producing Rockets and Missiles

• 1850 Employees including 950 Engineers

• Two facilities:

– 5,700,000 m2 Open Area

– 80,000 m2 Closed Area

About Roketsan

5

Mission

• To serve in the national defense with our rocket and

missile systems

• To contribute to the technological infrastructure of

our country with our products

About Roketsan

6

Vision

To become the leading establishment of our country with our rocket

and missile systems, from the depts of the seas to the heights of the

sky; to be placed among the first 50 companies which direct the global

market with their sales volumes and missile technologies, by means of

our own original products and advanced technologies

About Roketsan

7

Capabilities

• Design and Development of Rocket - Missile & Weapon Systems

• Technology Development

• Production and Test Technologies

– Rocket / Missile Integration

– Composite Solid Propellant & Explosive Production

– Precision, Plastic and Composite Part Production

– Environmental, Static Firing and Flight Tests

About Roketsan

8

Products

About Roketsan

9

Milestones

Oracle Footprint at Roketsan

10

• Oracle EBS 11.0.3 Implementation Project (May 2000 – Mar 2001)

• 11.5.9 Upgrade Project (Sep 2004 – Dec 2004)

• R12 Implementation Project (Aug 2012 – Dec 2012)

• MES – Paperless Production Implementation Project (Dec at 2012 –

Feb 2014)

General Info


11

• Oracle 12.1.3 is being used now

• In 2014 (projection),

– 7200 Job Orders

– 430,000 Move Transactions

– 600,000 Material Transactions

– 1,500,000 Clock In

Modules


12

• Discrete Manufacturing

• Quality

• ASCP

• Financials

• Purchasing

• Engineering

• Human Resources Man.

• Enterprise Asset Man.

• Project Management

• Primavera

• Hyperion

• MES

Purpose of the Project

Purpose and Scope of the Project

13

• Redesigning all Production Processes

• Adaptation of all Production Processes to ERP

• Monitoring Production Instantaneously

• Collection of Manufacturing and Quality Data

• Using Statistical Process Control Methods

• Standardization of Reports

• Minimizing Human Faults

Scope of the Project

Purpose and Scope of the Project

14

• All (58) Shop Floors in Roketsan

• All (1442) Stakeholders in Production System

• All Projects Carried Out in Roketsan

• All Production Documents and Processes

• Configuration and Change Management

Challenges In Implementation

15

• First Implementation in Turkey

• 25 years corporate culture

• Process Variety

• Product and Project Variety

• Project Scope

• Size of the Project Team

• Energetic Area

Main Changes with MES

• Monitoring Production Offline with

5 Employees

• Limited Data about Employee and

Equipment Utilization

• Hard to Prepare Genealogy Reports

Using Hard Copy Travelers

16

After

• Monitoring Production Online Using

MES

• Online Data about Employee and


• Easy to Reach Genealogy Reports

on the System

Before



5 Employees





17

• Monitoring Production Online

Using MES




on the System

Before After



5 Employees





18


MES




on the System

Before After



5 Employees





19


MES




on the System

Before After



5 Employees





20

Before


MES




on the System

After



5 Employees





21


MES




on the System

Before After

Developed Applications

22

• 20 new screens and extensions

• Using Oracle Forms, OAF, ADF, WCC and WorkflowPersonalizations & Extensions Routings ECO Collection Plans MES Operator MES Supervisor ...

New Screens Technician’s Cockpit Document Management Conformity Assesment MES Live Broadcast XML Reports with QR Code ...

Change Management for Routings

Personalizations & Extensions

23

Integration of Routings with WCC for document attachment

Personalized MES Operator Screen


24

Fields hidden, reordered and added

Extended Backflush Components Screen


25

Various validations added into buttons

Technician’s Cockpit

New Screens

26

Document Management - Before

New Screens

27

Job Traveler Before MES

Document Management - After

New Screens

28

XML Publisher based Job Traveler

Document Management - Before

New Screens

29

Discrepancy Report Before MES

Document Management - After

New Screens

30

Discrepancy Report After MES

MES Live Broadcast - MESSI

New Screens

31

Project Calendar

32

Project Facts

33

• 20 new screens and extensions

• 9 new XML Reports

• 70 Project Members

• 1450 Project Stakeholders

• 37 Training Sessions

• 20,000 man-hour direct labor (Roketsan)

• 101 day consultancy

Achievements

34

• Biggest IT Project in Roketsan

• ERP usage capability for technicians

• Additional 2.1 million ERP

transactions/year (520% increase)

• 7/24 Serving IT Infrastructure

• Multiple Database

• Redesign and Simplification of Production

Processes

• Instantaneous Traceability

• Easily Accessible and Analyzable Data

• Standard Reports for Various Level of

Management

• 2.8% Decrease in Production Labor Cost

MES Workstation

35

Future Projects

36

• MES & PLM (Product Lifecycle Management) Integration

• ASCP (Advanced Supply Chain Planning)

• BI APPS (Business Intelligence Applications)

• MSCA (Mobile Supply Chain Applications)

• Shop Floor Simulation

Questions and Answers

37

Thank you for listening