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Do you know MESA?
Digitizing the Supply Chain - New Product Development & Introduction
(NPDI)MESA unConference
May 5, 2014
Platinum Keystone Sponsors Gold Keystone Sponsors
The power of knowing what MESAKNOWSCopyright 2014, MESA International
Format for this Session
• What is an Unconference?• MESA Content to start discussion• MESA Working Group hot topics• Discuss your questions and expertise• Create action items for MESA
Learn from each otherExperience what MESA Knows!
The power of knowing what MESAKNOWSCopyright 2014, MESA International
Introductions
Erik Nistad, Mondelez InternationalDirector, Enterprise Business Services,Integrated Supply Chain Standards & Solutions,Vice Chairman, MESA Americas Board
Mike Williams, The Dow Chemical Co.Recently RetiredMESA Americas Board Member at Large
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The power of knowing what MESA KNOWSCopyright 2014, MESA International
Introduction to MESA International
MESA is…
…building bridges-of-understanding from the Plant to the Enterprise
…to drive clarity on the role and value of modern Information Technologiesin production operations
The power of knowing what MESA KNOWSCopyright 2014, MESA International
How MESA Delivers
Speaking with the Voice of Industry’s Practitioners
Peer-to-Peer
Global Education Program
Points-of-
View
MESA International:Building Bridges-of-Understanding from the Plant to the Enterprise
The power of knowing what MESAKNOWSCopyright 2014, MESA International
MESA’s Working GroupsRecipe Transformation Working Group• Founded in mid-2013• Focused on establishing a common
“language” for transforming a formula or bill-of-material into an executable recipe.
• Open for new members (must join MESA to participate)
• Chaired by Erik Nistad, Director, Enterprise Business Services, Integrated Supply Chain, Mondelez International
• Contact: [email protected]
The power of knowing what MESA KNOWSCopyright 2014, MESA International
Why are we (you) here?
The power of knowing what MESAKNOWSCopyright 2014, MESA International
There is a Better Way
• Common Language to define how to make a product• Common meaning and structure for the information• From Laboratory to Pilot Facility to Production
Facility• Between production facilities for technology
transfers• Across production stages
The power of knowing what MESAKNOWSCopyright 2014, MESA International
Your Ideal process
• The ideal process has:– Information created only
once– Information is available to
all parts of the company that need it
– Information is guaranteed correct and up to date, and
– Information is understandable by all parts of the company and suppliers
The power of knowing what MESAKNOWSCopyright 2014, MESA International
The Real Process
• Unfortunately in the real process:– Information is lost and
must be rediscovered – Groups work on
incomplete information– Groups work on out of
date information– The information is
inconsistently understood– Information is not shared
with suppliers
The power of knowing what MESAKNOWSCopyright 2014, MESA International
Enterprise Recipe Management
• Standard Process Descriptions for products for:– Technology Transfers– Site sourcing decisions– Investigations & Studies– MES and Batch Startup– Co-development– Sustainability
• ERM is a STRATEGY not a tool– It is a method for faster technology transfers– It is a method to support faster investigations and better production data
collection– It is a method to reduce the time and effort required to build production
(Master) recipes– Captures site best practices for more consistent multi-site quality
The power of knowing what MESAKNOWSCopyright 2014, MESA International
ERM Information
• Information for automated technology transfers• Definition of equipment independent manufacturing
processes• Information for QbD (Quality by Design) Design
Spaces• Information for lean manufacturing studies• Information for multi-site investigations• Information for sustainable manufacturing• Information for contract manufacturing • …
The power of knowing what MESAKNOWSCopyright 2014, MESA International
Why ERM
• Increased Regulatory Agency confidence with our processes– Same structure / format across all sites
• Recipe development down to days instead of months
• Consistent approach to recipe development across sites for product transfer
• Faster / More RFT Development
• Will achieve a higher level standardization of manufacturing process – Following industry standards & learning
from others
• Improving site to site knowledge of processes (sharing)
• Supports basis for site to site supply chain evaluation (standardized processes)
The power of knowing what MESA KNOWSCopyright 2014, MESA International
The ERM Concept
Standard Process Descriptions for Products
based on
Standard Definitions of Manufacturing Operations
using
Standard Quality Attribute Definitions (CQA, KQA)
and
Standard Process Parameter Definitions (CPP, KPP)
and
Standard Process Report Definitions
ERM
The power of knowing what MESAKNOWSCopyright 2014, MESA International
Automatic, Executable Recipe Generation
• Has anyone tackled automatically converting info from NPDI to “executable recipes”?
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Three Processes
• Creation of a core set of process actions• Creation of site specific, equipment constraints• Creation of General Recipes
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Core Processes Implemented By A Team Of SME’s
• Create a core library of Process Action definitions
• Create a core library of Equipment Constraint definitions.
• Create sample General Recipes for existing products to validate the libraries.
• Maintain the libraries and distribute to the sites and R&D.
The power of knowing what MESAKNOWSCopyright 2014, MESA International
Processes Implemented By Site Process Experts (SPE)
• Create and maintain a local library of Recipe Segments that implement the process actions on the site’s equipment.
• Create and maintain the equipment maps that define the layout and material flows through the site’s equipment.
• Create, using the transformation algorithms defined later in this paper, master recipes from the General or Site recipes provided by the core team or R&D.
The power of knowing what MESAKNOWSCopyright 2014, MESA International
Processes Implemented By R&D
• Create General Recipes as the definition of how to manufacture a product, using the definitions in the Process Action and Equipment Constraint libraries
• As new processes are developed, work with the SMEs and the SPEs to develop and define additional Process Actions and/or Equipment Constraints.
The power of knowing what MESAKNOWSCopyright 2014, MESA International
Output Are Libraries Used In ERM• A Process Action definition library• A library of Process Parameter definitions, used in Process
Action definitions• A library of Quality Attribute definitions, used in the Process
Action definitions• A library of Units of Measure, used in the process action and
Equipment Constraint definitions• A library of Process Report definitions, used in the Process
Action definitions• An Equipment Constraint definition library• Site recipe segment libraries• General recipe libraries
The power of knowing what MESAKNOWSCopyright 2014, MESA International
Automation
• With these definitions and libraries it is then possible for software to automate the creation of master to control recipes for a specific site
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Questions?
• What do all of you think?
• Does this make sense to you / your organization?
• Has anyone been able to cost justify an ERM type approach?
The power of knowing what MESA KNOWSCopyright 2014, MESA International
Barriers To NPDI Introduction And Operational Excellence
Original slides extracted from 2003 MESA report by EDSReference to MESA white paper PLM GuidelinesUpdated for MESA 2014
Mike K WilliamsMESA memberThe Dow Chemical Company – retiredrepresented 2014 MESA –Industry Week UnConference
Acknowledgement:
The power of knowing what MESA KNOWSCopyright 2014, MESA International
Typical NPDI Environment
Develop & ScaleProduct
Enterprise Recipe Mgmt
Shop floor Execution
ERP
eBOM missing• Material Composition• Equipment Capability
Design – Planning – Manufacture
Product Scheduling
Process ControlR&D
Supply Chain
Manufacturing
The power of knowing what MESAKNOWSCopyright 2014, MESA International
Are these your current processes?
ExecutePlan
Shop Floor
Line 1
Line 2
Line 3
Line n
Design
•Work instructions•ECO’s•Routings•MBOM
•EBOM•Drawings•Models•Specs•ECO’s
1st Transformation 2nd Transformation
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Now imagine coordinating a Refinery
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The integrated view
ERPERP
Process Definition
Process Definition
ProductDefinition
ProductDefinition
ShopFloor
Execution
ShopFloor
Execution
• E-BOM• M-BOM• Characteristics• Prod. Configuration
Production Orders
Product ProducedMaterial ConsumedMachine Time utilized
Reconciliation andChange Requests
• Process Configuration• Op. Routing• Work Instructions• Consumables• Characteristics Assignment• Shop-floor Reqs.
• Tooling• Data Collection fields• Operator Certification
Configured work package
The Waltz has three steps:• PLM• POM• OEEEnterprise Recipe Management
- The glue
The power of knowing what MESAKNOWSCopyright 2014, MESA International
Benefits of Integrated POM-PLM-OEE• Creates an unambiguous communication
from product and process definition to the point of manufacture
• Configuration management applied to product and process derive work package for a specific work order
• Direct, associative re-use of product definition data right to the shop
• Feed back to design and supply chain planning:– on production performance– Process capability
• Creates an unambiguous communication from product and process definition to the point of manufacture
• Configuration management applied to product and process derive work package for a specific work order
• Direct, associative re-use of product definition data right to the shop
• Feed back to design and supply chain planning:– on production performance– Process capability
• Fast, accurate change implementation
• Delivers the right data, right time and place
• Avoids data re-entry error• Saves time and skilled labor• Expedites Product and
process improvement • Provides improved CAPEX
utilization
• Fast, accurate change implementation
• Delivers the right data, right time and place
• Avoids data re-entry error• Saves time and skilled labor• Expedites Product and
process improvement • Provides improved CAPEX
utilization
The power of knowing what MESAKNOWSCopyright 2014, MESA International
More Resources• MESA Whitepaper: June 2013 – “Using General Recipes for Standardized Multiple
Plant Manufacturing Science”• MESA Whitepaper: November 2008 – “Manufacturing Science Model Extensions
to Address Lean Manufacturing and Lean Supply Chain”• MESA Whitepaper: November 2008 – “An Iterative Refinement Approach
towards a Structured Recipe Design”• MESA Whitepaper: March 2008 – “Manufacturing Science Model Extensions to
Address Product and Process Sustainability”• MESA Whitepaper: April 2003 – “General to Master Recipe Transformation,
Capturing Best Engineering Practices in Recipe Generation”• MESA Whitepaper: October 2002 – “From a Corporate Product Specification to a
Control Recipe: It's not a Transatlantic Trip”• MESA Whitepaper: October 2002 – “General Recipe: Multiproduct Facility
Design; Technology Transfer”100s of materials available to Premium members
at no additional charge
The power of knowing what MESAKNOWSCopyright 2014, MESA International
Why MESA?Global community for improving Operations Management with IT
Best practices & guidance to drive productivity & profitability
Global Education Program raising competency for production IT success
Facilitate innovation for real-time Plant to Enterprise (P2E) integration
Be heard and drive industry forward
Join the conversation at: www.mesa.org
The power of knowing what MESA KNOWSCopyright 2014, MESA International
To Improve Your Success…
www.mesa.org
The power of knowing what MESAKNOWSCopyright 2014, MESA International
Thanks for Participating!MESA Enterprise Recipe Transformation Working Group
www.mesa.org
Erik Nistad, Mondelez InternationalDirector, Enterprise Business Services,Integrated Supply Chain Standards & Solutions,Vice Chairman, MESA Americas [email protected]
Mike Williams, The Dow Chemical Co.Recently RetiredMESA Americas Board Member at Large
photo
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The power of knowing what MESAKNOWSCopyright 2014, MESA International
Thanks for Participating!
Moderator #2 NameJob Title/MESA TitleContact info
Moderator #3 NameJob Title/MESA TitleContact info
Logo (if applicable)
Logo (if applicable)
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www.mesa.org