Customized MES Systems
An MES (Manufacturing Execution System) is the backbone for Industry 4.0. Today even SMEs (small medium enterprises) have to face the market pressure to make their manufacturing processes more transparent and gain overview of all operations in a central platform. However, the daily production pain points differ for each factory, therefore the implemented MES functionalities and modules should be tailored to the actual necessities.
SINNEO provides customized MES solutions according to the exact specifications given by our customers. The system development is done in close cooperation with our proven engineering partner, Com-Forth Ltd.
Com-Forth is a family owned, innovative industrial IT company with a team of over 20 skilled software engineers. Established in 1988 in Budapest, Hungary, Com-Forth serves its global system integrator and manufacturer customer base with over 30 years of industrial IT expertise.
Some characteristics of manufacturing "life" without MES:
Production output: necessary to keep large finished product stock to keep up with the changing order inflow.
Manual processes: high possibility of failures in manual operations, causing low efficiency and high scrap percent.
Machine availability: unplanned downtimes can reduce production capacity even up to 40%.
Product quality: large raw material inventory necessary to compensate for unpredictable output quality.
Production data: process data is not available for analysis, thus output losses and quality issues remain undiscovered.
Process control: inflexible process control pulls back capacity growth.
Energy consumption: growing energy costs affect profitability.
Our customized MES solutions are built upon the following architecture:
The core components of the system:
Automatic Data Acquisition: connect production assets to the factory LAN network (or to a cloud-based database) and automatically collect the required data tags. The data is typically acquired from PLC-s, from sensor signals or from local machine databases.
Manual Data Entry: we provide stationary or mobile HMI terminals for the operators (PC workstations, tablets, PDA-s, etc.) for manual data collection.
OPC to SQL Gateway: in most cases we apply an OPC-UA software solution for processing the collected data tags and logging these into an SQL database.
Authentication & Authorization: secure-by-design data transmission between each components of the system based on Windows Active Directory.
MES Engine: it contains the customer specific Business Logic, a digital twin of the production units, processes, products, etc. The MES Engine also handles data flow management between the SQL database, the function modules and the client applications, as well as event and exception handling. The customer can integrate own applications (reporting, data handling, etc.) via REST API interface.
Customized function modules: fully customized functionalities according to customer requirements. The most common function modules of our MES system:
- OEE: real-time monitoring and reporting of equipment OEE
- Track & Trace: full-scale traceability for production materials and processes
- Andon: real-time production displays on the shopfloor
- QA: quality tracking and analytics
- Scheduling: production planning and dispatching (production machines – work orders – operators)
- WIP: Work in Progress material tracking
- CMMS: smart maintenance management module
- SPC: detailed Statistical Process Control calculations and reports
- Routing: PLC-based routing control between production stations
- HR: employee attendance tracking, competency matrix, etc.
Client applications: fully customized, HTML5-based web clients. The user interface is tailored to meet the customer’s needs (logo, colors, fonts, layout), in bilingual design (English – Chinese).
ERP connector: customized, uni-directional (download order information) or bi-directional (order status feedback) data interface to any ERP system.
Average ROI on MES projects, based on realized applications
|Lead time||30% less|
|Machine utilization||20% more efficient|
|Production planning time||50% shorter|
|Reaction time to unexpected changes||Minutes instead of days|
|New project deadlines||100% on time|
|Process bottlenecks||Identified and treated before issues occur|
|Lack of materials||Identified and handled before affecting the production|
But where to start...?
Adopting an MES system in manufacturing can be demanding, so where should you start the process?
Some general guidelines:
- Start with a simple, small-scale project (for instance OEE, process data acquisition, production scheduling, etc.). Focus on solving a real pain point in your production, with real business value.
- Define a pilot project and follow-up the implementation strictly.
- Must assign a dedicated project manager or DRI (Directly Responsible Individual).
- After a successful pilot-project scale up the solution step-by-step to further machines and systems (one machine to production line, production line to production hall, etc.).
- The ROI of one project can justify and finance the next project, to ensure management's approval.
We are honoured and excited to empower our customers with practical MES tools to solve their every day production issues. We are keen to drive greater value to your business by enabling a smarter, connected way of manufacturing.