国际商务项目管理论文-Applying a Phased Approach for a Successful Manuf
时间:2012-06-29 13:33:40 来源:www.ukthesis.org 作者：英国论文网 点击:333次
| Applying a Phased Approach for a Successful Manufacturing Execution System (MES) Project WHITE PAPER(由留学生论文网整体提供） 19 A Mesa International and Citect co-branded white paper. 10.4.06 Applying a Phased Approach for a Successful Manufacturing Execution System (MES) Project ©2006 MESA International. *Images in this document are trademarked by Citect and MESA International. Applying a Phased Approach for a Successful Manufacturing Execution System (MES) Project ©2006 MESA International. *Images in this document are trademarked by Citect and MESA International. 1 APPLYING A PHASED APPROACH FOR A SUCCESSFUL MANUFACTURING EXECUTION SYSTEM (MES) PROJECT As industrialized nations must compete more often against low manufacturing costs in developing countries, manufacturing businesses are implementing Manufacturing Execution Systems (MES) to increase productivity, improve quality and reduce downtime. Typically MES solutions are associated with improvement initiatives such as LEAN, Six Sigma, TQM, TPM, among others. By gaining greater visibility into the plant floor and individual production lines, manufacturers gain valuable information on root cause disturbances and production slowdowns. Many of these disturbances are barely visible in manual reporting processes, yet when identified and corrected businesses can achieve big gains in productivity and quality. Other reasons for implementing an MES solution include increasing the visibility of product and work flow throughout the enterprise to optimize labor – every company’s most precious and often most expensive resource. A detailed AMR Research report notes that a typical MES solution “paid for itself on traditional cost reduction measures within 6 to 24 months of going live.”† There are many examples where companies received a payback in less than 6 months and some as soon as a few weeks after installing an MES solution. For example, Adelaide Brighton Cement, Australia’s only national cement supplier, achieved a 50 percent reduction in stoppages just one month after implementing its MES solution. In addition to improving production performance and quality, many manufacturers are turning to MES solutions as a means for increasing production to meet market demand without investing in new machinery and plants. An example of this is found in the coal industry. After many stagnant years, the coal industry has encountered a huge demand increase as a result of record-breaking oil prices and expanding manufacturing in Asia. Coal processing plants must immediately increase production in order to take advantage of growing market demand; they must get every ounce of production out of existing equipment and facilities as soon as possible. The manufacturing industry faces similar issues when competing with offshore manufacturing vendors, where productivity#p#分页标题#e# improvement must offset lower costs. Although many manufacturers are under considerable pressure to implement a solution right away, it is important to properly evaluate an MES solution. An evaluation process in which certain criteria are met by the solution provider will help ensure the MES solution you select correctly meets your needs. In turn, the solution provider should be able to demonstrate a project methodology that will facilitate a successful initial implementation and can be later expanded to other areas or additional plants. This paper examines the characteristics of a reliable solution provider as well as one approach to implementing a methodology that begins with an initial project that can later be easily duplicated across the business. † Swanton, Bill. “MES Provides Long-term Revenue and Market Benefits Beyond Easy-to-Quantify Operational Cost Savings.” AMR Research report. July 2003. ©2006 MESA International. *Images in this document are trademarked by Citect and MESA International. 2 Applying a Phased Approach for a Successful Manufacturing Execution System (MES) Project Engaging the Right Solution Provider Finding a trustworthy and competent solution provider is the first step in attaining the MES solution that will meet business objectives. Arriving at a simple, easy-to-use MES solution is a complex process. Manufacturers will usually achieve better results when they select an overall solution provider instead just buying software alone. A solution provider will analyze your business challenges and define and implement a solution that helps you achieve the business value you seek. Therefore, it is important to engage a solution provider who can provide a thorough assessment of your needs and determine the MES solution that will meet your objectives. Selecting a solution provider is about choosing a partner who thoroughly understands your needs from a business, technological and management perspective. All these solution perspectives should be carefully considered because a failed project is the most expensive project. Attributes of a complete solution provider/partner: • Provides the practical experience, professional services, and technology enablement necessary to deliver the correct solution • Creates a holistic solution that fits the needs of the business and its objectives • Provides professional services needed to ensure optimal configuration • Offers training to instruct plant personnel how to maintain and expand the system at later stages • Delivers continuous support long after the project is implemented • Conducts periodic workshops and reviews to ensure optimal usage • Ensures the system can be expanded to the full enterprise without significant redevelopment costs • Endeavors to provide a low total cost of ownership (TCO)#p#分页标题#e# ©2006 MESA International. *Images in this document are trademarked by Citect and MESA International. 3 Naturally when evaluating a solution, cost is an important factor. An MES solution is a component of a continuous improvement strategy that is by nature an ongoing process. Therefore, factoring all the costs, not just the initial cost, will help you to accurately assess the return from your investment. Selecting the lowest upfront cost may be more expensive over time. Evaluating the total cost of ownership (TCO) is important when deciding which MES solution to deploy. You should consider several items when evaluating TCO: • How much time will it take to maintain the system? • What skills are required to maintain it? • What product training is required to run the system? • After the software is installed, can it be maintained independently? • If the solution is expanded to a second location, what kind of cost reduction in services can be expected? • How are productivity and quality gains measured, and what improvements are expected? • What are the ongoing support capabilities and costs from the provider? These questions are directly affected by the relationship with the solution provider. Whether choosing a large or a small company, the solution provider should understand your specific needs as well as offer a solution that can easily grow and change with your business. Determining Exactly What You Need from an MES Solution Provider This question may seem simple, but it must be addressed before starting the implementation. MES solutions can greatly enhance the results obtained by today’s continuous improvement strategies like Six Sigma, Lean, and Total Quality Management. These improvement strategies all require the ability to gather timely and accurate measurements of a process in order to create improvement initiatives. A strategic and comprehensive approach to implementing an MES solution is essential to the project’s success. A methodology should be applied to establish the overall program and determine exactly what the MES solution should provide. A solution provider who partners with your business will work with you to define the stages that facilitate a smooth initial implementation and subsequent rollout. Applying a Phased Approach for a Successful Manufacturing Execution System (MES) Project ©2006 MESA International. *Images in this document are trademarked by Citect and MESA International. 4 Manufacturing Enterprise Solutions Support for Demand Driven Enterprises The Benefits of a Phased Approach How the project is run is just as important as how the project is specified. For the best results, a phased approach and methodology is recommended. In general there are seven major phases of the project:#p#分页标题#e# 1. Engage 2. Discover 3. Define 4. Design 5. Develop 6. Implement 7. Optimize All seven phases are critical to the success of the project and require a high-level of agreement and interaction to work properly. The solution provider and the user should reach an agreement on milestones, objectives and critical success factors that ensure that each phase has been successfully completed. Phased Approach to Implementing the Right MES Solution* Goals for Define Phase(由留学生论文网整体提供） ©2006 MESA International. *Images in this document are trademarked by Citect and MESA International. 5 Manufacturing Enterprise Solutions Support for Demand Driven Enterprises Each phase of the project – from engaging the right solution provider to implementing the solution – builds on the prior phase. As the business objectives are defined in the Engage and Discover phases, the manufacturer is able to successfully ascertain the metrics and process improvement strategies necessary for implementing the correct MES solution that will ultimately fulfill the business objectives laid out in the first phases. Step 1– Engage The engagement phase is used to select and appoint the leadership and key stakeholders who have been identified as the decision makers in the project. An MES solution is truly a joint venture between the solution provider, leadership and the end user. Therefore, a team combining members from both companies – the manufacturer and the solution provider – is the starting point to implementing an MES solution. It also forms the initial building blocks needed to build the desired relationship between both companies that will set the standards for the entire project. It is equally important at this stage to determine who will be the users and include representation from the users to ensure their input is heard as they are often more familiar with the plant floor requirements and challenges. The Engagement phase identifies: • Key shareholders • Leadership team • Decision makers • User community Step 2 – Discover The discovery phase is undertaken by the solution provider to assess the impact to people and process elements across the organization to ensure the MES team understands the business’ challenges. It is critical the solution provider comprehends the business objectives associated with the project and the technical challenges they will face in order to have the insight needed to define a solution. This phase must bring clarity to the overall implementation strategy. The discovery phase determines: • Prioritized business objectives • Potential ROI and benefits • Technical assessment of current technical architecture#p#分页标题#e# • Continuous improvement assessment ©2006 MESA International. *Images in this document are trademarked by Citect and MESA International. 6 Applying a Phased Approach for a Successful Manufacturing Execution System (MES) Project With any continuous improvement strategy, the business objectives must be clearly outlined and agreed upon by leadership. Management must work with the solution provider to identify and prioritize areas of operation with the highest probability of return. At a later stage, the solution will need to include the processes and behaviors that may also be changed to fully realize the targeted value. This information will be used to define the strategy and approach used to ensure a successful solution implementation. Therefore, identifying the business objectives with the greatest potential effect is crucial to implementing the solution that will have the most efficient and effective impact on the company/plant. This will lead to Key Performance Indicators (KPIs) selection. The purpose of the KPIs is to give people quick information on how the business and manufacturing processes are currently operating. These KPIs will be put into place and begin being monitored during the design phase to measure the improvements and the value being returned of the implementation. KPIs vary from business to business depending on the ultimate objective of the solution. Whatever KPIs are ultimately selected, it is important to limit the KPIs to a small number to ensure they can be initiated and monitored. As we will see later, KPIs evolve and new KPIs are added as performance improves and new challenges are added. Step 3 – Define The definition phase determines the strategy and approach that will be followed for the project. By clearly defining the project’s scope based on business objectives, additional critical information can be identified and documented. High-level business requirements and baseline metrics will be finalized in this phase. The more mature and complete these requirements are, the better the project team will understand the change management needs and the implementation strategy. The definition phase determines: • Project scope • Business process baseline and metrics • High-level business requirements and critical-to-quality measures • Change management needs regarding stakeholder assessment, communications and training • Recommended implementation ©2006 MESA International. *Images in this document are trademarked by Citect and MESA International. 7 This phase more than any other phase is the most critical to the success of the project and the associated costs. The outcomes of this phase affect over half the project’s success criteria. The decisions made can adversely affect the associated costs over a hundred fold if#p#分页标题#e# the decisions are changed later in the project. Frequently companies will rush this phase to get to the next two phases – design and develop – with the idea they will see faster results. Consequently, this approach usually leads to incomplete requirements, scope slippage, and time/budget overruns. Any one of the previously mentioned challenges can single handedly cause a project to fail and be cancelled before completion. Project Scope This can be the most challenging work of the project as it involves political, emotional and logical aspects. It also may cross numerous user communities with drastically different perceptions of what is needed by the business. Therefore, it is critical to understand the reasons why users are passionate about their needs and how they can be met by the project. By using a priority based approach, each requirement can be listed in order of importance based on key factors such as scope of impact, return on investment, budget and effort required. Only after these criteria are agreed upon and understood can a feasible list of requirements be created to finalize the project’s scope. Additionally, by leveraging a phased approach, the requirements that do not make the initial implementation can be reevaluated at a later time if a subsequent release is scheduled. Again, the same process must be followed to ensure that the project’s scope is documented, clearly understood and communicated with the support of the leadership team. Business Process Baseline and Metrics It is important to be able to measure both the current situation and the progress as the business operations improve in order to determine a business’ current, past and anticipate future state. A baseline of information supported by specific metrics will need to properly reflect these measurements. These metrics also known as KPIs and are organized in a progressive order that constitute a KPI tree in which values role up into other values. For example, a machine’s production values may roll-up into production line values that roll-up into a department, followed by the plant, etc. As alluded to earlier, KPIs are a dynamic picture of business operations. As operations improve new KPIs may be needed as new goals are added. This perpetual cycle must be a part of a bigger picture that supports process improvements, which systematically change and evolve. Applying a Phased Approach for a Successful Manufacturing Execution System (MES) Project ©2006 MESA International. *Images in this document are trademarked by Citect and MESA International. 8 Applying a Phased Approach for a Successful Manufacturing Execution System (MES) Project Change Management Needs To prevent an MES solution from being just another source of data, a change management initiative running in conjunction can determine success or failure. Data without analysis#p#分页标题#e# provides little information, and information without improved processes and changed behaviors provides few results. In simple terms whether it is trial and error, improved training, or utilizing industry standard best practices, there are better ways of conducting business that will provide better returns. “Soft” challenges, such as user acceptance, must also be considered in order for the project to succeed. Recommended Implementation Simply put, “If you fail to plan, plan to fail.” One of the most frequently overlooked phases of the project is the implementation plan. Any implementation plan can look very simple on paper. However, many other aspects, which may not have been considered, may need to be included in order to properly plan. For example, high demand periods and vacation seasons can virtually eliminate resource availability as well shut-downs for plant turnovers that can eliminate the availability of data and even electricity. These are just a few of the challenges outside the technical area that need to be accounted for in an implementation plan. A good implementation plan really needs to tie all of the ends together: communications, planning, release scheduling, training, testing and more. By developing this plan in conjunction with known implementation challenges, the business can significantly improve the project’s success factors. Step 4 – Design The design phase begins by the finalizing business requirements documented in a business requirements document (BRD). The BRD is used as the basis and control for the detailed solution design and the technical architecture that will be developed. It is critical the BRD is not developed in a silo, and an accurate cross-section of the business, user and the engineering communities are involved to ensure a successful project. A change management plan should also be created from the input gathered in the earlier stage to ensure the end user roll-out is accepted and successful. All projects must account for the effect on the users, the existing processes and the technology in order to facilitate the needed behavior changes and to obtain the results identified in previous phases. ©2006 MESA International. *Images in this document are trademarked by Citect and MESA International. 9 Applying a Phased Approach for a Successful Manufacturing Execution System (MES) Project Additional documentation should also be drafted or completed during this stage to communicate the overall design and architecture that will be implemented as well as quality assurance methods and commissioning schedules. It is essential that management be fully engaged to ensure the project is widely adopted and promoted. Management should make sure the users are allotted the proper time to assess the solution and for training. If management does not make this a priority and schedule accordingly, it is#p#分页标题#e# unlikely users will take time from their busy day to adopt the system. The design phase should also be used to develop work plans, milestones, exit criteria and a quality management plan. The design phase determines: • Detailed business requirements • Overall solution design • Required technical architecture • Development plans and controls Once the objectives of this phase have been met, projects often leverage pilots at this stage to determine solution feasibility, to secure additional funding and executive support, or to further mature estimates and timelines before moving forward into a complete rollout. Goals for Define Phase* ©2006 MESA International. *Images in this document are trademarked by Citect and MESA International. 10 Applying a Phased Approach for a Successful Manufacturing Execution System (MES) Project Pilot versus Complete Rollout After management has agreed on the objectives which the MES solution needs to achieve, it must then determine how to implement the solution. There are basically two approaches for implementing an MES solution – performing a pilot or doing a complete rollout. While a full rollout may appear similar in time, the full rollout involves more effort and significantly higher organizational risk than a pilot. It is important to remember that expanding the MES solution to other production lines and plants can be done more rapidly and less expensive after a successful pilot. Most companies chose to implement the MES solution in a plant or one part of a plant as a pilot that can then be replicated across the business. Therefore, we will refer to the following stages as part of a pilot. Choosing the Pilot Location When selecting the area for an MES pilot, you should examine several characteristics: 1. What location best represents the other locations for the planned rollout? 2. What location has the most progressive personnel who welcome new ideas? 3. What production area is fairly contained? The third question is very important because you need to select a location in which the results from the MES solution will be most evident in the quickest time. For example, a packaging line is often a good choice because it deals with finished goods with very little input from needed from other production lines. In general, a pilot should not take more than three months to complete. If you choose an area that is too large, implementation will take a very long time. Conversely, an area without network access or outdated hardware will require additional costs and make the pilot more risky. Ideally, a small functional area of the facility where operators, maintenance and support staff interact with the system on a daily basis is the best candidate. All users can be trained at one time so they will help reinforce each other’s#p#分页标题#e# knowledge of the new system. ©2006 MESA International. *Images in this document are trademarked by Citect and MESA International. 11 Championing the Pilot to All Participants After selecting the area in which to implement the pilot, attention turns to the workers who will be affected by the pilot. Once again management must be involved just as in the initial project phases to promote success. Communication is crucial because some workers may feel burdened by the new system or fear it will measure individual performance. As many industrialized nations must compete against the developing world for manufacturing jobs, workers are keenly aware of the importance of quality and productivity as determining factors for keeping their operations from being relocated to other countries. Management and workers alike can benefit from understanding an MES solution helps them remain competitive by increasing productivity and quality with the equipment they currently have. It is very important to create a communication plan that motivates the people impacted by the pilot. The plan should communicate clearly the pilot is intended to measure and improve processes, not individuals. If the participants understand the pilot will not be a value judgment about their performance, the likelihood of getting good feedback and clear measurements increases greatly. Operations The operations team will be the first group impacted by the pilot. MES systems can appear as management checking up on operators. Consequently, honest and ongoing communication with this group is key. It is very helpful to create a focus group of operators who can add an important plant-floor perspective and champion the pilot to the workers. Any technical issues must be resolved quickly to maintain operator confidence and interaction with the system. Other groups that need to be considered are: • Quality/Continuous Improvement department • IT/MIS department • Maintenance department • Engineering department Although different companies have different titles and various job descriptions, there is always someone performing these roles. Applying a Phased Approach for a Successful Manufacturing Execution System (MES) Project ©2006 MESA International. *Images in this document are trademarked by Citect and MESA International. 12 Applying a Phased Approach for a Successful Manufacturing Execution System (MES) Project Continuous Improvement Department This department decides the direction of the pilot. Along with executives, they set the KPIs that determine the pilot’s critical success factors. They will also be important in delivering clear communications about the significance of the MES solution. IT/MIS Department The IT department is an important technical evaluator of the proposed solutions. IT should#p#分页标题#e# be involved to ensure the MES application will integrate with existing systems. The IT department should also be involved and accountable for specific IT related tasks during the pilot. The pilot could involve installing new computers and servers that will need to be managed and maintained. Organizational standards must also be created if they do not exist, to ensure IT standards for all servers, networks, and security systems are maintained. This step will make it much easier to support and scale the MES system later. In addition, the IT department will need to assess the complexity of interfacing with the higher level and lower level systems. Engineering Department The engineering department should be capable of supporting and expanding the MES system because of the addition of new equipment and upgrading of existing equipment. Thus, engineering must be consulted during the evaluation process to determine how to best support the MES system. Off-the-shelf MES software packages usually minimize the learning curve and allow engineers to easily configure the software. The engineering department also typically provides possible opportunities for future value-added functionality. ©2006 MESA International. *Images in this document are trademarked by Citect and MESA International. 13 Applying a Phased Approach for a Successful Manufacturing Execution System (MES) Project Reliability/Maintenance Department The maintenance department is engaged before implementing the pilot. They need to be informed of possible changes and additions to the plant floor equipment. The pilot may include new plant floor hardware and equipment such as network cards, bar code readers and other input devices whose maintenance will be the responsibility of the maintenance department. If the key performance indicator (KPI) is to optimize maintenance against performance to increase asset utilization as part of an overall equipment effectiveness (OEE) initiative, the maintenance department will be a key participant in the MES pilot. The maintenance department can be as important as the operations department in ensuring the MES system is used properly. Typically this part of the project includes the components listed in the diagram below.* ©2006 MESA International. *Images in this document are trademarked by Citect and MESA International. 14 Applying a Phased Approach for a Successful Manufacturing Execution System (MES) Project Step 5 – Develop By the time you reach the development phase, the pilot should have been completed. The pilot will have provided an important real-world implementation that will facilitate the development phase beyond the contained area of the pilot. For example, a pilot may have been performed on a packaging line and the development phase will integrate the experience from the pilot with the development of a larger solution for the entire#p#分页标题#e# production line. The development phase of the project is the primary responsibility of the MES solution provider. The provider should maintain an open, but structured environment to ensure productivity is not compromised. However, it is also critical the end-user community is involved throughout the process for periodic reviews. Evaluations are conducted to ensure the business objectives are still relevant and being met. Additionally, regular communications and workshops should occur to provide further information to the solution provider and status updates to the stakeholders. The development phase delivers: • A solution based on the business requirements • A technical architecture based on design Prototype Creation A prototype in some form is frequently used to ensure users’ expectations are being met and minimal development efforts have been spent. Information from the pilot is very useful for creating the prototype. Lessons have been learned, and all early input from the users helps to determine the basic software configuration as well as the screens the operators, plant managers and executives (if applicable) will utilize. Internal Review Knowledge transfer during configuration depends on a number of factors including end user skill sets and the amount of ownership the end users will take during the rollout. One global manufacturer recently discovered the importance of incremental operator training during an MES solution rollout. This progressive manufacturer believed in placing the MES tool in the hands of the operators instead of engineers or analysts since operators have the biggest impact on improving productivity. The goal of making operators use the MES solution to effect positive change required both training and coaching. The company initially provided extensive and detailed training showing the operators the entire breadth of solution’s capabilities. However, management soon found that inundating the operators with too much knowledge did not help them retain the skills they needed to use the tools. ©2006 MESA International. *Images in this document are trademarked by Citect and MESA International. 15 Applying a Phased Approach for a Successful Manufacturing Execution System (MES) Project The training was then modified to provide tailored displays and views with simple interfaces. Daily coaching followed the training. Operators became more familiar with using the MES solution, but still were not bridging the gap between seeing the information and using it to make positive changes. The manufacturer then implemented high-involvement activities that engaged the operators and provided goals and incentives. A training coordinator was assigned to the group to answer questions regarding how to best use the MES solution. As soon as the#p#分页标题#e# operators saw the MES solution as a tool to provide important productivity information that they could use to increase output, they began to effectively use the MES solution as a tool in their daily production activities. The involvement activities were the key in teaching the operators how to use the relevant information provided by the MES solution. The operators then could use the information for immediate feedback on the machine performance and this empowered them to take immediate, corrective actions. Step 6 – Implement The implementation phase is used to deploy the solution and integrate the solution usage into daily business activities. This phase will need to involve change management activities and training, but most importantly executive support to ensure the implementation is a priority to the business. The collection of KPIs and other key metrics is irrelevant if not supported by leadership and process improvements. The MES solution converts data to information, but the supporting activities are what converts information to knowledge and this is what initiates the changes that will fulfill the objectives set out in the early phases of the project The implementation phase develops: • User understanding and acceptance • Executive and operator training • Improved processes tied to MES information • Changed behaviors tied to MES information ©2006 MESA International. *Images in this document are trademarked by Citect and MESA International. 16 Applying a Phased Approach for a Successful Manufacturing Execution System (MES) Project Testing and Customer Acceptance As the solution is being created, iterative testing should occur. The MES solution provider and the end user should review any changes to functional documents. Once the configuration is ready to be tested, the MES solution provider should internally perform a complete system test for review against the FRS (this term is not used in previous sections – need to have it defined where the FRS is built – I assume this is a Functional Requirements Study maybe? Not sure where this document is defined/built). This is a key project milestone. One of the items to consider when choosing an MES solution is if the solution provider has a proper testing environment that can simulate the production environment. This allows any potential problems to be identified and corrected before the actual site commissioning begins. Even though a pilot may have already been performed on site, each location is different and will require testing before being implemented. While site commissioning is important and unavoidable even with the best testing environment, a testing environment separate from the actual site can greatly improve and expedite commissioning. After finishing the complete system test against the FRS, the next step is to perform an#p#分页标题#e# integration test. The integration test demonstrates to the end user the system is complete and ready for the initial installation. This is a critical step for customer review and acceptance; it is where problems that could impact the project’s success need to be evaluated. The customer should include the operations staff that will use the system. This ensures operational issues are identified prior to installation. Only after everyone on the project team is convinced the MES solution is ready for installation at the site should the next phase of the project begin. ©2006 MESA International. *Images in this document are trademarked by Citect and MESA International. 17 Applying a Phased Approach for a Successful Manufacturing Execution System (MES) Project Site Commissioning and Customer Acceptance While site commissioning can be the shortest duration phase of the project, it is by far the most critical. Typically during this phase, the users begin operating the system. Other items that should be covered during this phase of the project: • Operator training • Administrative and programming training • User training on data analysis • Customer review of information Once the system is operational, all training and final acceptance testing should be done on the system to remedy any final issues. As seen in the earlier example of a global manufacturer, training should begin as soon as possible since it often requires modifications to be effective. The project implementation occurs when the entire project team performs all required tasks, the operators are using the system and management is seeing benefits. The diagram below* shows how all parties are involved in this stage: ©2006 MESA International. *Images in this document are trademarked by Citect and MESA International. 18 Applying a Phased Approach for a Successful Manufacturing Execution System (MES) Project Improved Processes Tied to MES Data Crucial information gathered should have been documented to make a “best practices” document. The MES solution provider’s project manager may use these documented practices to replicate prior successes or make adjustments to accommodate any challenges recognized during the implementation phase. For example, a milk processing plant is concerned about quality issues and spoilage. The plant measures how long it takes for the milk to move from pasteurizing to bottling to determine if there is an unseen delay. After implementing an MES solution, they find a high level of spoilage by tracking quality. Root cause analysis shows that bottling is running at 100% without delays and therefore nothing they can do to reduce delays in the process. Instead of finding a delay however, the MES solution shows the bottles are moving too quickly through the pasteurization process. The pasteurization line problem is#p#分页标题#e# corrected so the milk is delivered to bottling with the proper processing time. This was identified by the MES solution tracking when the milk left pasteurizing department to when it was received in bottling versus spoilage rate. The extended time is the root cause. This information led to a process improvement, slowing down the pasteurizing department, as a result of the data provided by the MES solution’s tracking of the process. Changed Behaviors Tied to MES Data Lastly, a benchmark should be taken at installation for measurement purposes. Periodic reviews and workshops will need to be done to ensure optimal use of the system. By having this benchmark in place, the business will be able to chart progress, uncover hidden problems and ensure the system is used to the optimum performance. ©2006 MESA International. *Images in this document are trademarked by Citect and MESA International. 19 Applying a Phased Approach for a Successful Manufacturing Execution System (MES) Project Step 7 – Optimize the solution The optimize phase is used to fine tune the new solution and how it is being used now as well in the future. Critical KPIs change over time as operating improvements occur and make new priorities more visible. Frequently, businesses do not realize they had a problem ‘B’ until problem ‘A’ is fixed. Therefore, it is very beneficial to have a solution provider with business and technical expertise to ensure the solution’s capabilities are maximized. At this point in time, the partnership formed throughout the project synergizes as the lines that originally existed between the two companies are no longer visible. The MES provider assumes the role of a new trusted advisor to assist the company in optimizing the solution to meet new challenges. The optimization phase develops: • Fine tuning the solution and its outputs • Improve levels of competence around the currently configured solution • Periodic analysis of data and challenges to provide new roadmaps Fine Tuning MES projects, just like process improvement initiatives, are continual. MES solutions offer even bigger returns when they are used to drive continuous improvement, not just for cost reduction measures. The initial implementation may need optimization and fine tuning. This fine tuning should be done in conjunction with the MES solution provider because it has the best understanding of how to analyze and optimize the solution. This part of the project needs to be viewed more as a long-term transition to rollout. The MES solution provider should do an extended handoff to help the users understand how to interpret the data and how to modify the system to meet their future needs. Periodic Analysis of Data and Challenges to Provide New Roadmaps The continuous improvement team will continue to analyze the results and data to improve#p#分页标题#e# process and behaviors. As a result of teamwork and training, they should feel confident enough with their MES solution to implement small changes themselves. By this time, it is also hoped the MES solution provider has become a trusted advisor who can be called upon for larger changes or updates. ©2006 MESA International. *Images in this document are trademarked by Citect and MESA International. 22 Applying a Phased Approach for a Successful Manufacturing Execution System (MES) Project Conclusion As industrialized nations feel increasing pressure to compete with lower operating costs in the developing world, the importance of continuous improvement strategies and automated visualization tools that enhance these strategies will achieve paramount importance. While it has been shown that adding automation tools to continuous improvement plans often exponentially increases results, it is important to apply a methodology to determine exactly what is to be achieved through the use of the MES solutions tools and how to select the right MES solution. Perhaps as important as the MES solution itself is the relationship between the customers and solution providers. This relationship manifests itself in their collective commitment to partner together to develop the best MES solution to meet the customer’s goals and objectives. ©2006 MESA International. *Images in this document are trademarked by Citect and MESA International. 23 Applying a Phased Approach for a Successful Manufacturing Execution System (MES) Project Authors Christine Lesher, Citect Ed Patzsch, Citect 30000 Mill Creek Avenue, suite 300 Alpharetta, GA 30022 Tel: 770.521.7511 ©2006 MESA International. *Images in this document are trademarked by Citect and MESA International. 24 Applying a Phased Approach for a Successful Manufacturing Execution System (MES) Project About MESA: MESA promotes the exchange of best practices, strategies and innovation in managing manufacturing operations and in achieving plant-floor execution excellence. MESA’s industry events, symposiums, and publications help manufacturers, systems integrators and vendors achieve manufacturing leadership by deploying practical solutions that combine information, business, manufacturing and supply chain processes and technologies. Visit us online About Citect: Citect is a global provider of industrial automation, real-time intelligence, and next generation manufacturing execution systems (MES). Leveraging open technologies, Citect's solutions connect to multiple plant and business systems. Our CitectSCADA/HMI, Ampla, Nexa and Meta solutions are complemented by Professional Services, Global Customer Support and Educational Services. Our solutions are found in over 80 countries and numerous industries: mining, metals, food and beverage,#p#分页标题#e# manufacturing, facilities, water, gas pipelines, power distribution and pharmaceuticals. (由留学生论文代写网整体提供）Headquartered in Sydney Australia, Citect has representation in Oceania, Southeast Asia, China and Japan, North and South America, Europe, Africa and the Middle East.(责任编辑：www.ukthesis.com) |
论文价格：免费