What this presentation includes

• MES Introduction
o Why MES
o Functions of MES
o Levels of MES
o How does MES works
o Data flow from PLC to IGS to iFIX to Proficy
o Benefits of MES
o Types of Production System
o Different Tools of MES
o Responsibilities of MES
• Industrial Standards
o ISA 95
o GMP
o MESA
o OSHA, FDA, EPA regulations and ISO 9000 family
• Upcoming Technologies
o Industry 4.0
o Digital Manufacturing
• Comparison between different MES Tools
• Extension of MES
 Why MES

MES provides information that helps manufacturing decision makers understand how current
conditions on the plant floor can be optimized to improve production output. 
MES works in real time to enable the control of multiple elements of the production process
(e.g. inputs, Staff, machines and support services).
An MES manages simple to complex manufacturing processes, including areas where multiple
production lines, and control stations are used.
The system optimizes movements of goods and enables complete control and visibility over
raw materials, work in progress, to finished goods, throughout the manufacturing process
 Functions of MES

A manufacturing execution system (MES) is an information system that connects, monitors and controls
complex manufacturing systems and data flows on the factory floor. The main goal of an MES is to ensure
effective execution of the manufacturing operations and improve production output.

MES’ core functions include:

• Data collection and acquisition
• Operations / Production Scheduling
ERP • Dispatching Production Units
• Production Tracking & Genealogy

MES • Staff and Resource Management and Status

• Process Management
• Performance Analysis
Historian, OPC, iFIX • Maintenance Management
• Quality Management
• Document Management
Sensors, PLC & SCADA
 Levels of Manufacturing Execution System

Business Level
ERP
ERP/Sales/R&D/Executives

MES
Plant Level
MES Engineer

Historian, OPC, iFIX

PC&IS
PLC & SCADA, Historian, OPC

Plant SSO/Operators
Production/Quality/IT Operations
Sensors, PLC & SCADA
 How does MES works
• Production Plan • Recipe ERP is being used
ERP • Bill of Material to create and
manage the basic
• Production Steps
plant schedule i.e.
production,
material use,
• Production and Downtime tracking • Order Management delivery and
MES • Quality result per Lot • Series Number shipping, making
• Maintenance Scheduling • Quality Management information the
centre of the
operation.
• Software interface MES is used to
Historian, drive the
• Buffers the data
OPC, iFIX manufacturing
• Data Acquisition and Data Management
operation, by
managing and
reporting on plant
• Detects Weight, Volume etc. activities as
Sensors, PLC
• Detects running and fault code of machines events occur, in
& SCADA
• Motion control, Process control, Distributed Control Systems, and Networking real-time.

MES works as a functional layer between ERP and Process Control System on the factory floor, giving real time workflow
visibility, flexibility and insight into how best to improve enterprise-wide manufacturing operations.
• Recipe
 Data Flow from PLC to Proficy
Data Sent in Raw Format Data Sent in Raw Format

iFIX Data

Acknowledgement Acknowledgement

GE iFIX, IGS OPC server and proficy event models are used for collecting & transferring Downtime, Waste and splice data to Proficy
System from PLC. IGS and IFIX will provide seamless connectivity with Proficy Plant Application.

What is IGS
 IGS is Industrial Gateway Server.
 It acts as the OPC server.
 It has many nodes for devices where the tags are configured.
 All the data from PLC to Plant Applications passes through IGS.
 PLC sends raw data like : Year, Month, Day, Hour, Minute, Second,
MilliSec, MachindId, MsgInBuffer, MsgsInfo, MsgsLost, BufferFilling,
Trigger, Sequence, Autocause, StartEnd, ReurnSeq to IGS.
What is IFIX
 IFIX acts as OPC client and server.
 Used to get real time data as Historian is not fast enough to get data
that comes in a millisecond difference.
 It has PDB(Process Database) where all the tags are configured and the
current data for all the tags can be seen.
 IFIX has many schedules to collect data based on events.
 Schedules and PDB in IFIX makes csv files so that Historian file collector
can read data and store it in tags.
 The data which is received by IGS is sent to IFIX and stored in the tags
on PDB.

The MES interface enables simple, highly reliable data connectivity between automated machinery and manufacturing-related computing
applications, such as Manufacturing Execution Systems (MES) and Production Control Systems (PCS).
 Data Flow from PLC to Proficy
PLC Tags IFIX PDB tags
Year IFIX PDB ta gs Year
Month confi gure d us i ng Month
Day Downtime Messages cha nnel a nd Devi ces Day
Hour Hour
Minute Minute
Second Second
IFIX:
MilliSec MilliSec
IGS: Schedules are
PLC: MachindId MachindId
Channels and Devices are configured which will
Downtime Messages MsgInBuffer MsgInBuffer
created trigger on change in
MsgsInfo MsgsInfo
Trigger tag
MsgsLost MsgsLost
BufferFilling BufferFilling
Trigger Trigger
Sequence Sequence
Autocause Autocause
StartEnd ReturnSequenceNum ReturnSequenceNum StartEnd
ReurnSeq ReurnSeq
Me s s a ge i s cl ea red a t PLC Si de Once CSV fi l e genera ted,s che dul e
wi l l wri te ba ck re turn s equence
to PLC Sche dul e s wi l l genera te
.cs v fi l e wi th s ta te a nd fa ul t ta g
Hist File collector Tags va l ue wi th ti me s ta mp
Year
Month
Downti me Me s s a ge buff er ta gs Day
a re confi gured wi th cha nnel Hour
a nd devi ce na me Minute Sta te a nd fa ul t ta gs a re i nput to
Historian:
Second Historian: Profi cy eve nt model
Downtime Message Proficy:
MilliSec Historian File
buffer tags are 211 Downtime model is
MsgInBuffer Collector processes
configured configured and will be triggred
MsgsInfo .csv and fetch data
on state tag value and insert
MsgsLost from .csv into
event into GBDB
historian tags

Autocause
StartEnd
 Benefits of MES

• Manufacturing cycle time

• Data entry time
• Work-In-Process
• Paperwork between shifts
• Lead times
Reduces • Setup cost, Inventory & Downtime

• Product Quality
• Planning Process
• Customer Service
Improves • Uptime
• Productivity

• Eliminates lost paperwork

Reliability • Empowers plant operations people
• Provides end to end visibility
• Root cause diagnosis and issue
resolution
• Electronic batch/device history records.
 Types of Production System

Continuous/Repetitive Production
Intermittent / Non-continuous Production system
systems

Batch Production
Project Production Job Shop Production Process/Continuous-
(Produced in
(Large Contracts and (Varieties of Product Mass/Flow/In-Line flow Production
Lots/Groups and
Projects for production) produced in small Production (24X7 Production
Batches)
amounts) round the year)

Product Variety

Product Volume
 Intermittent/Non-continuous production systems
• Manufacturing takes place in discrete batches, or groups rather than flowing continuously.
• Intermittent means, something that starts (initiates), and stops(halt), at irregular(unfixed) intervals(time gaps).
• The production system keeps changing according to the design, and size of the product (This system is very flexible).

Project Production Job Shop Production Batch Production

A product or service based
Description production system, where a
company accepts a single, complex
and large contract in form of a
project. The order must be
completed within a given period of
time and estimated cost.
Each item has their own
processing route, and takes
different paths where small
batches of a variety of custom
products are made. Here most
of the products produced
require a unique set-up and
sequencing of processing steps.
Batch production occurs when
many similar items
are produced together.
Each batch goes through one stage
of the production process before
moving onto next stage. The
Production of items takes place in
lots / groups/ batches.

Example Construction of airports, dams, Paint shops, Machine tool shops Medicines, Computer chips,
roads, buildings, ship building, Clothing, Jet Engine
transport system, movie production,
drilling of oil rigs etc.

Classification High Product Variety, Low Product Low to Medium Product volume, Medium Product volume, Medium
Volume High to Medium Product variety Product variety
 Intermittent/Non-continuous production systems
Project Production
The order must be completed within a
given period of time and at an estimated
cost. Examples of project production
The production process is concerned
with transforming a range of inputs into
those outputs that are required by the
market. This involves two main sets of
resources - the transforming resources,
and the transformed resources.
Job Shop Production
Advantages:
• Product usually high quality.
• Producer meets individual customer needs
• Greater job satisfaction – involved in all stages
of production
Dis-advantages:
• Cost of producing one unit or job is higher.
• Labour –intensive.
• Requires investment in skills and training
Job shop production system is a system that
manufactures one or few quantity of products
which are designed and produced as per the
specification of customers within prefixed time
and cost. The distinguishing feature of this system
is low volume and high variety of products
Batch Production
Batch production is a method
of manufacturing where identical or
similar items are produced together for
different sized production runs. The
method allows for products to be mass-
produced in batches with small to major
changes to the product, from car doors
through to children's toys.
i) The volume of output is generally
large and goods are produced in
anticipation of demand. ii) The material
should be as per the specifications and
should be delivered on time. iii) The
product design and the sequence of
operations must be standardized
The advantages of batch production are
that its cheaper to produce a whole
batch instead of single, machines can be
used more effectively. It's lower cost,
fewer workers because going to use
machines.
 Job Shop production
• The production lines are running separately and are producing different products at the same time.

Finished bottles Finished bottles Finished bottles

Job production, where

items are made
individually and each item
is finished before the next
one is started. ...
Batch production, where
Production Production Production
groups of items are made line 1 line 2 line 3
together. ...
Flow production, where
identical, standardised
items are produced on an
assembly line.

100 units Green 100 units Blue 100 units Black

coloured bottles coloured bottles coloured bottles
 Continuous Repetitive systems
• The mass production facilities that produce high volumes of the same products.
• Manufacturing happens mostly in Automated and special-purpose equipment's.
• Petrochemical, cement, steel, sugar and fertilizer industries etc. uses continuous systems.

Process/Continuous-Flow production Mass/Flow Production

The Production is continuous, 24X7 hours all The production can be broken down to small
Description round the year. Same type of products flow repetitive continuous task.
continuously through a linear process.

Example Oil and Gas refineries, petroleum refineries, Canned goods, Cars, Washing Machines,
chemical processing, cement, steel, sugar Refrigerators etc.
and fertilizer industries

Classification High Product volume, Low Product variety Medium to Low Product volume, Low to
Medium Product variety
 Continuous Repetitive systems

Process/Continuous-Flow production Mass/Flow Production

In process production, the demand for the product In mass production, large numbers of identical products
is continuous and high. The materials can create different are made. Production is often continuous, and is suited to
products at different stages of manufacturing. Like in oil high demand, mass market products
refinery, this can be kerosene, gasoline etc

Continuous production system involves a continuous or Mass production, also known as flow production or
almost continuous physical flow of materials. It makes use continuous production, is the production of large amounts
of special purpose machines and produces standardized of standardized products, including and especially on
items in large quantities assembly lines.

The continuous flow process involves moving one work unit

at a time between each step of the process — with no
breaks in time, sequence, substance, or extent. For most
applications, continuous flow saves time, energy, and costs
and when implemented correctly, it can: Reduce waste
 Continuous Repetitive systems
Process/Continuous-Flow production
• Dedicated plant and equipment With zero
flexibility.
• Material handling is fully automated.
• Process follows a predetermined
sequence of operations.
• Component material cannot be readily
identified with final product.
• Planning and scheduling is a routine
action.
• Product differentiation is limited.
• Involves high initial investments.
• Most of the work is done by machines
rather than humans.
• Production is continuous, 24X7, round the
year.
Mass/Flow Production
• Mass production system are also referred to
as Repetitive Manufacturing Systems.
• Work-In-Progress (WIP) inventory is low
because the items move quickly in the plant.
• Products follow the same path.
• Both machines and humans work together
to produce products of similar types in huge
quantities.
• Production does not run continuously round
the year.
Machine A Machine B Machine C
Machine D Machine E
Different MES tools
 Responsibilities of MES

• Management of energy

Energy Management
• Automatic collection of

Machine Data
• Interfaces to all common
Configuration Data

counters and hierarchical pieces and quantities

machines structures
• Maintenance and • Automatic detection of
• Collection, visualization and production and downtime
management of all machines monitoring of energy
data records • Configurable shop floor
consumption monitor
• Select function for machine • Automatic alert system of
programs • Collection of downtime and
infringing target values failure modes
• Storage and upload of • Analysis of consumption in
optimized programs • Various overviews and
correlation with other evaluations including OEE
• Utilization statistics of production parameters
machine programs functions
• Consumption profiles to • Integrated maintenance
identify power peaks calendar
• Energy KPIs and planning • Interface to maintenance
strategies to improve your systems
energy consumption

Shop Floor level needs information and planning functions in the following areas:
 • Management of inspection • Management of tool • Display of capacity utilization

Tool and Resource Management

Process Data

Shop Floor Scheduling

characteristics and inventory • Taking into account all
measuring channels • Automatic collection of resources
• Assignment of inspection working and down time via • Improving set up times
characteristics, parts and BDE (shop floor data • Automatic machine
tools collection) and MDE assignment
(machine data collection) • Simulation of shift and
• Collection and storage of
• Maintenance of tools utilization rate changes
process values
• Assignment of tools within • Improving individual
• Monitoring of action limits detailed scheduling
and tolerance limits capacities
• Combining machine and tools • Monitoring material and
• Logging of process • Tooling history stock levels
interruptions • Down time monitoring • Various tables of overviews
• Online status of processes and evaluations
• Evaluations of process • Interface to ERP and PPS
interruptions systems
• Process logs
 • Transfer of orders / operations • Control and monitor material

Material and Production Logistics

Shop Floor Data

Tracking & Tracing

from ERP system • Collection of batch data in flow in production
• Generate production and the production • Inventory control (raw and
overhead orders auxiliary material / intermediate
• Overview of all active batches products / WIP) for production
• Creating collective orders, • Tracing batches containing • Display of stocks inclusive stock
splitting of orders / operations detailed information in a development across all sites
• Log on/off or interruption of table • Considering minimum storage
orders / operations • Graphical batch tracing (batch times and/or expiry dates
• Log on/off of personnel or tree / traceability) • Visualization of material buffers
groups • Complete documentation by between operations
• Configurable terminal dialogs means of a batch history • Alert and expiry statistics for
to collect all relevant order • Compliance with standards material with a limited shelf life
data (FDA, GMP etc.) • Calculation of range for material,
• Various overviews and • Triggering escalations by intermediate and semi-finished
evaluations identifying defined scenarios products.
• Immediate upload of real data • Triggering escalations by
to the ERP system identifying defined scenarios
MESA Model
As an educational
association, MESA
provides models
that help those from
a variety of levels
and disciplines within the manufacturing and
production enterprise to converge on common
views of what they need to accomplish and how
enterprise solutions can assist.  The objective is to
provide a platform for mutual understanding and
planning for increased performance.

• The current MESA Model, spans from

enterprise-level strategic initiatives to business
operations to plant operations and actual
production.
• It shows the interrelationships between
strategies, enterprise-level operations, and
plant operations. Objectives cascade down, and
results are reported up against those objectives.
• It also provides a conceptual illustration of how
events in the plant operation feed and inform
all other events, and how aggregate views from
the enterprise can drill down through
operations to the real-time production views.
 ISA 95 Model
ISA-95 defining MES by information architecture
Unlike the MESA model, which focused on business process, the ISA-95 model focuses on information architecture.
The ISA-95 model divides production systems into 5 levels.

ISA-95 standard helps define boundaries

between systems. Intelligent devices, such as
• Sensors, at Level 1.
• Control systems like PLCs , DCS, OCS, at
Level 2.
• MES, at Level 3.
• ERP at level 4.

By situating MES on Level 3, ISA-95 implies that

MES connect production with enterprise
systems, manage workflows to produce end
products, maintain records of production, and
optimize the production process.

The goal was to develop a standard that would

enable efficient interfacing and integration
between an ERP system and an MES. This
would facilitate effective communication
between stakeholders, lowering the total cost
of ownership and enabling error-free
integration.
 Good Manufacturing Process(GMP)

• GMP is short for Good Manufacturing Practice. It was enacted out of the concern that arose when companies produced health-
related products that were sub-standard, and thus, posed as a threat to human health.
• Good manufacturing practices (GMP) are a set guideline laid out by recognized agencies. These guidelines are designed to
ensure that food products, cosmetics, beverages, pills, and medicinal products meet up to a level of high quality. The regulation
covers a wide range of operations, from manufacturing to the control of the facility, to processing, to packaging and to
distribution.
• In recent times, the acronym “cGMP” is commonly used. It stands for Current Good Manufacturing Practices. Since older GMPs
are outdated, the new nomenclature helps to remind companies to make use of the updated systems, technologies and
operations. This will help to reduce the reduce the risk of error and impurity that are associated with older manufacturing
practices.
• Several GPMs are adopted all over the world. The two most popular ones are WHO GPM and FDA CGMP.
 Few More Industrial standards
• The United States Food and Drug Administration (FDA or USFDA) is responsible for protecting and promoting public
health through the control and supervision of food safety, tobacco products, dietary supplements, prescription and over-the-
counter pharmaceutical drugs (medications), vaccines, biopharmaceuticals, blood transfusions, medical devices, electromagnetic
radiation emitting devices (ERED), cosmetics, animal foods & feed and veterinary products.

• Environmental Protection Agency (EPA) regulations cover a range of environmental and public health protection issues, from
setting standards for clean water to specifying cleanup levels for toxic waste sites to controlling air pollution from industry and
other sources.

• The ISO 9000 family of quality management systems (QMS) is a set of standards that helps organizations ensure they meet
customer and other stakeholder needs within statutory and regulatory requirements related to a product or service. ISO 9000
deals with the fundamentals of quality management systems, including the seven quality management principles that underlie the
family of standards.
QMP 1 – Customer focus QMP 5 – Improvement
QMP 2 – Leadership QMP 6 – Evidence-based decision making
QMP 3 – Engagement of people QMP 7 – Relationship management
QMP 4 – Process approach
https://www.iso.org/files/live/sites/isoorg/files/store/en/PUB100080.pdf

• Occupational Safety and Health Administration (OSHA) was created to ensure safe and healthful working conditions for working
men and women by setting and enforcing standards and by providing training, outreach, education and assistance.
 Digital Manufacturing

https://www.capgemini.com/service/digital-services/digital-manufacturing/
Industry 4.0
Extension of MES