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Copyright 2011 MESA North American Conference
Changing MES platform within 4 months
Martin HubeňákIT Manager
Tyco Fire Protection Products
Copyright 2011 MESA North American Conference
Agenda
• TFPP Ráječko Site Introduction• Project Description• Original MES system• Documentation and process review• Process definition and modeling in new MES system• Implementation and migration activities• Project summary
Copyright 2011 MESA North American Conference
TFPP Ráječko Site introduction Ráječko located in Czech Republic, Central Europe
Manufacturing portfolio: PCBAs, Fire detectors, Call points, Nurse call, Smoke detectors
Over 1 100 product PNs Volume approx. 1.7 mil units/year Site space: total 17,000 sqm (183,000
sq ft) Employees 320 Years of service: 7,6 24/5 regime, 3 shifts
Ráječko
Copyright 2011 MESA North American Conference
Project description
• Replacing existing Shop Floor Control System• Replacing existing supporting applications like Shop Floor Reporting Label Printing Tester interface application
Project task
Copyright 2011 MESA North American Conference
Project description
• New flexible system applicable in various types of productions
• Opportunity to review and standardize current processes
• Support new quality and process standards• Open the system for integration with other systems like ERP
and PDM
• Minimize the using of customized activities
Benefits
Copyright 2011 MESA North American Conference
Project description
• Aggressive timeline 4 months for implementation
• Implementation of ERP, MES and PDM systems in parallel
• Needed resources shared with other projects
Risks
Copyright 2011 MESA North American Conference
Assumptions
• Evaluate the benefits of MES system.
• Separate task “MES cost justification” with result YES.• Quality, Operations, IT, SCM, FIN teams needed 3 months
to evaluate the MES project implementation.
• Decision regarding strategic MES platform for future.
MES system yes or no?
Copyright 2011 MESA North American Conference
Assumptions
• Adaptable platforms for various types of manufacturing processes
• Easy to identify and implement basic modules with option to extend the functionality in future.
• key to success - Reducing the requirements for end user training – systems can be designed to meet current valid work instructions.
• Flexibility for Global Operations
Opportunities during implementation of new MES platform
Copyright 2011 MESA North American Conference
AssumptionsExample of Tyco MES Operator Interface
Copyright 2011 MESA North American Conference
Assumptions
• key to success - Needed HW architecture prepared on time.• Decision regarding placement of application and database
servers – on site.• Decision regarding database platform and OS - Microsoft
against UNIX and Oracle used in former MES platform.• Implement solution for support applications like Label
Printing and interface with the test machines.
Hardware and Support applications
Copyright 2011 MESA North American Conference
Assumptions
• key to success - Creating skilled team is essential condition for successful result of the project
• Adequate sources on partner side
Competent team
Copyright 2011 MESA North American Conference
Assumptions
Tyco team:Project manager IT MES Project leaderOperations manager IT managerMES shop floor administrators Quality manager IT Developer ProgrammerQuality engineers Process engineersTest engineers ERP consultantPDM super user IT MES analyst
Competent team
Copyright 2011 MESA North American Conference
Project Scope• Manufacturing flow at shop floor Modeling of routers/processes Starting from order creation and release Ending at packing of finished goods
• Finished goods WIP inventory management Declaration at the end of production line Counting of finished goods stock Real-time visibility
Copyright 2011 MESA North American Conference
Project ScopePreparation
Assembly
Inspection
Test
Packing
Manual
Repair
Serial Number Release, Label Printing, Component Validation
SMT (Surface mounting), component trace
Component trace, product configuration
Quality control
Automated test
Alternative flow
DebugRepairDisassemblyScrap
Multilevel packingLabeling
Copyright 2011 MESA North American Conference
Project Scope
• Semi-finished goods WIP inventory management Counting Visibility
• Two way communication with test machines
• One way communication with line scanners
• Two way integration with ERP system
• Reporting
Copyright 2011 MESA North American Conference
Project Scope
• Quality management Ad-hoc quality data sampling Basic quality sampling planning Ability to hold/release entities
• Contextual work instruction visibility
Copyright 2011 MESA North American Conference
Systems architecture, original status
Label Printing app.
Reporting app.
Data Warehouse
Tester Interface app.
ERPDB PDMDB
MESDB
Copyright 2011 MESA North American Conference
Systems architecture, current status
Reporting app. Tester Interface app.
ERPDB PDMDB
MESDB
Copyright 2011 MESA North American Conference
Original MES system
• Site’s former MES system was SCE 3.0.1.1. Data stored in Oracle 9i.
• Loftware was used as printing solution (MES system sending PAS files to Loftware)
• Test machines were connected to SCE sending there results and failure diagnosis, parametric data and/or SLIP files
Copyright 2011 MESA North American Conference
Original MES system
• Data were pulled from MES database to Data Warehouse (DW) in 30mins cycles. Oracle Report and Oracle Discoverer tools were used for reports‘ design.
• Note: SCE was used for many years, was very well tuned and customized to fully support business requirements for product tracking and quality outputs. Consumed components as well as finished goods were automatically backflushed into ERP system.
Copyright 2011 MESA North American Conference
Project schedulePhase / Task / Milestone ScheduleProject Kick Off – Planning and Prep 23/08-29/08Blueprint & Realization Iteration 1 30/08-03/10Blueprint & Realization Iteration 2 04/10-24/10Blueprint & Realization Iteration 3 25/10-14/11Blueprint & Realization Iteration 4 15/11-05/12Conference Room Pilot 15/11-28/11Final Preparation (Deployment) 13/12-23/12Go Live and Stabilization 03/01/2010Project Completion and Transition to Support
03/01-17/01
Copyright 2011 MESA North American Conference
Documentation and processes review
• key to success - All production processes were carefully documented
• Benefit - almost no process changes identified (processes constantly improved in the past)
• Due to very short time for new system implementation it would not be reasonable to proceed with major changes at the same time.
Copyright 2011 MESA North American Conference
Documentation and processes review• Example of document which describes Pack functionality
Copyright 2011 MESA North American Conference
Process definition and modeling in new MES platform
• Partner consultants were modeling and accommodating MES system based on their methodology and our requirements in four iteration steps (4 weeks each).
• Each step started with definition of the processes involved in the step and ended with user acceptance tests.
Copyright 2011 MESA North American Conference
Process definition and modeling in new MES system
• At the end of fourth iteration all essential features/functionalities were available (serial number tracking, component traceability, backflush of consumed components into ERP system and so on).
• Rest of processes identified as non-critical (like RMA support, Change production, Time-Based Traceability) were implemented after go-live.
Copyright 2011 MESA North American Conference
Process definition and modeling in MES
Copyright 2011 MESA North American Conference
Processed definition and modeling in MES
Copyright 2011 MESA North American Conference
Implementation, partial go-live
• First implementation step, partial go-live• Build few identified PNs in new MES in the mid of December• key to success - experience with the new product on the
shop floor• Demonstrate, that the system is ready to support at least
most critical production phases• Rest of production was still traced in former MES system
Copyright 2011 MESA North American Conference
Implementation, Production Data Migration
• Production master data like process flows, products definitions, BOMs needed to be set in MES.
• Two options to set product data used Manually due to complexity key to success - migrated using various developed scripts
to pull the data from former MES’s underlying Oracle 9i and send them into new MES’s MS SQL 2008
Copyright 2011 MESA North American Conference
• key to success - without such automation of data migration we would not be able to set all needed data as there are hundreds of products and product revisions being build
Implementation, Production Data Migration
Copyright 2011 MESA North American Conference
Implementation, Cut Over
• Cut Over – production stop, week between Christmas and New Year
• key to success - Cut Over plan – coordination with ERP project
• Physical Inventory required• Testing interface between new ERP and new MES systems• Testing interface with line testers/machines• Set and test all production Zebra printers
Copyright 2011 MESA North American Conference
Implementation, Cut Over
• key to success – WIP transfer• Programs in VBA code needed all unfinished SNs in existing MES introduced into new
MES system after that moved to the correct position in their process
flow• SNs with open non-conformances were placed in queue for
the test operation they failed so by retesting them we got the NC data into MES and had no missing data.
Copyright 2011 MESA North American Conference
Label printing
• Zebra printers used
• Variety of label layouts is small• Decision not to use any label printing
software but to use Zebra’s ZPL code and just replace parameters with real values before sending ZPL to the printer.
Copyright 2011 MESA North American Conference
Label printing
• Currently there are about 25 different label designs and 15 Zebra printers on the Shop Floor (mainly supporting PACK operation).
Copyright 2011 MESA North American Conference
Tester Interface
• There are various test machines like incircuit testers, functional testers, optical inspection machines.
• There are many various applications and operating systems (old versions of Windows but also HP Unix).
• key to success - New interface application developed in Java enabled all test machines connection with MES without any change on tester side.
Copyright 2011 MESA North American Conference
Tester Interface• The interface application was essential as there was not
enough time and resources to do the change for each test machine.
Copyright 2011 MESA North American Conference
Reports• Various production and quality reports have been developed
in MS Reporting Services.
Copyright 2011 MESA North American Conference
Summary
Go-live started on January 3rd when all production started to be traced in new MES system.
Meet the deadline Meet the budget Stable system, no outage from Go-live date (9 months) Excellent Production and Quality KPI’s – MES system
justified
Copyright 2011 MESA North American Conference
Summary, MES justification
• Quality First Pass Yield – 96% DPPM – 0
• Costs Productivity (working hours utilization) – 100 % CC (# of customer complaints) – 0
• Delivery OTD-R (on time delivery based on 1st commit) – 97%
Copyright 2011 MESA North American Conference
Key to success, assumptions
• No requirements for end user training – applicable MES platform
• Needed HW on time• Motivated competent team, project management• Documented processes• Programmer, database specialist• Excellent team on partner side – Thank You
Is it possible to replace MES system within 4 months?YES, in case that:
Copyright 2011 MESA North American Conference
Thank You