TRACKING PROCESSES.REDEFINING EFFICIENCY.An Intelligent Approach to Manufacturing

MANUFACTURING EXECUTION SYSTEM

Engineering,Research &

Development

PRODUCTDEVELOPMENTIS AT THE CORE

OF EVERYTHINGWE DO

We empower our clients to make their product

dreams a reality by designing, engineering, validating

and industrialising better products.

Unlike any other organisation in our sector, beyond

engineering and product development, we've had the

curiosity to pursue the optimisation of end to end

manufacturing. The result is a complete

understanding of the benefits associated with the

digitalisation of modern manufacturing.

Architected well, the complete product realisation

lifecycle is a virtuous feedback loop designed to

embrace the data that supports the continuous

improvement of better products.

Tata Technologies leverages over 25 years of cumulative knowledge

and experience to help the world's leading manufacturers to create

great products and to select, deploy and adopt the technologies that

underpin the entire product realisation lifecycle. Drawing on a

combination of people, process and technology, we drive efficiencies

and innovation to help our clients meet the design, engineering and

production challenges.

CONNECTING THEMANUFACTURINGENTERPRISEConnected Enterprise IT solutions from Tata

Technologies enables businesses to optimise the

application of technology for the manufacturing

sector, removing critical data discontinuities and

enabling a platform for the complete digitalisation

of modern manufacturing. Our vast experience of

product development and manufacturing

engineering helps provide enterprise-wide visibility

of the key performance indicators of seamless

manufacturing execution.

WHY TATA TECHNOLOGIES?

• Enabling smart connected factories

• Delivering global solutions for digital manufacturing

• Extending the digital lifecycle into effective manufacturing with

ERP, MES, SCM, CXM, businesswide analytics and intelligence,

complemented by world-class Application Maintenance Services (AMS)

• Other legacy IT systems

CONNECTED

ENTERPRISE IT

SOLUTIONS(CEIT)

Manufacturing Enterprise IT

Process to Create

Capacity to Create

Manufacturing Execution System

For companies to achieve sustainable competitive

advantage in today's rapidly changing business

environment, they must deploy Intelligently different

solutions that respond to market changes both quickly

and effectively and help adopt production processes – in

real-time. A critical tool to achieve this is an efficient

manufacturing execution system (MES) that supports

timely execution.

Reduced time-to-market, demand for lower costs,

enhanced productivity and quality, maintaining track,

trace and genealogy records and a robust materials

management system are the challenges the

manufacturing industry is facing today. Fierce global

MANUFACTURE INTELLIGENTLY BY IMPROVINGDECISIONS FROM SHOP FLOOR TO TOP FLOOR

OPTIMISED PROCESSES.

SMARTER MANUFACTURING.

competition, rapidly changing business environments, cost

pressures, improving quality and increasingly complex

supply chains that need to be managed with agility are

major issues manufacturers around the globe are

constantly addressing. Demand changes driven by global

markets are highly volatile and therefore it is beneficial for

an organisation to implement a flexible, agile and robust

manufacturing operations management system. Customer

satisfaction, profitability in a cost-effective manner and

ensuring delivery commitments are the need of the hour

and therefore MES provides complete visibility and

control over their shop floor operations apart from a

tighter control on supply chain.

Tata Technologies delivers customised

Manufacturing Execution Systems (MES)

that enable informed decision-making and

identification of opportunities for improving

the production process. Deep domain

knowledge about complex manufacturing

processes, business issues and the

technologies required to improve

operational efficiencies are what our

practitioners specialise at. Backed by a

value-focused approach to ensure ongoing

simplification and Total Cost of Ownership

(TCO) reduction, our Subject-matter

Expertise is testimony to our 25+ years of

close association with leaders in the

automotive, aerospace and industrial heavy

machinery manufacturing sphere. Our

innovative capabilities and best-of-the-

breed consulting and implementation

services for MES solutions deliver

immediate business value and enable

organisations to realise the power of the

integrated enterprise, ultimately resulting in

business growth.

LEADING EDGE

SEE YOUR SHOP FLOOR LIKE NEVER BEFORE

Reduced manufacturing

cycle time by an average of

45%

Reduced data entry time by

75%

Reduced Work In Progress

(WIP) by an average of

24%

Reduced lead time by an

average of

27%

Reduced paperwork between

shifts by an average of

61%

Reduced product defects

by an average of

18%

Industry surveys recommend that businesses implementing and using an MES experience quantifiable changes

in profitability, quality, productivity and process performance. These can be summarised as shown below:

OURVALUE

PROPOSITION

Solution Roll-out• Multi-site Roll-out• Platform Migrations• Program/Project Management• Change Management

Integration Capabilities• MES-ERP• MES-Control System/CNC Integration• ISA 95 - Standard• Custom Integration

Consulting• MES Scan• Opportunity Assessment• MES Technology Product Evaluation• MES Consulting-IT and Automation Integration Landscape

Solution Design and Implementation Approach• Standard COTS Products Based Solution• Modular and Comprehensive• State-of-the-Art

Reporting Solutions• Standard Reports and Dashboards• KPI Measurement/ Operational Intelligence• Email Notifications• SMS Alerts

AMS Multi Level Support• Onsite• Offshore• Onsite/Offshore Mixed

Manufacturing Execution System

SERVICE OFFERINGS

Integration and InterfacesProduction Order Management

Performance Management

• Shop Floor Control Systems

Test Equipment and Data•

Loggers, LIMS

Enterprise Resource Planning•

PLM•

SCM•

Warehouse Management•

IT Systems•

• Data sources - Excel, Access,

SQL, Oracle

• Mobility Solutions

• Make To Stock (MTS) and Make

To Order (MTO)

Work Order Management•

Scheduling and Resequencing,•

Substitution and Dispatching

Work Order Broadcasting•

Materials Flow and Complex•

Routings (Rework/Repair)

Work Order Visibility•

Throughput Management•

Production Monitoring and Control•

• Reporting

Enables Plant Operations Visibility•

Overall Equipment Efficiency• (OEE)

Process and Plant KPIs•

Production and Downtime Reporting•

Product History and Analytics•

ANDON and Real-time Annunciation•

Maintenance Management•

Facility Monitoring and Controls

Inventory Management Quality Management

• Energy Monitoring and

Consumption Optimisation

Utilities Management•

Real-time Consumption Trends•

Warning Alerts•

Safety Alerts•

Consumption Reporting and•

Billing Management

Carbon Footprint Reduction•

• Kitting Accuracy

Kanban/JIT/JIS•

Line Side/Workstations/•

Inventory Management

Super Markets Management•

Vendor Managed Inventory (VMI)•

• In-line Quality

End of Line Quality •

Quality Containment•

Closed Loop Quality Control•

Defect Capture and Analysis•

SPC•

Regulator Compliance•

Lean/WCQ/TPM•

Audit Trail•

ERP

Industrial loT

MES

» Rockwell Automation

» GE

(Tata Technologies Customised Application)

Domain

» Automotive

» FMCG

» Industrial Heavy Machinery» Tyre

Sh

op

Flo

or

ERP

MES

» MS SQL

» Oracle

Database

» Factory Magix

PLC

»

» Siemens

RockwellAutomation

SCADA

» Siemens

» GE

» RockwellAutomation

Track, Trace and Genealogy Error Proofing

Real-time Production Tracking with•

Build history

Machine, Operation Status, WIP•

Visibility

Capturing Critical Process Values•

Operator Accountability in Decision•

Support

Material Traceability (Lot/Serial)•

Data Capturing of Critical Parts•

and Aggregates

Child Parts to Final Product•

Consumption/Raw Material•

Warranty and Recall Management•

• Pick to Light

Digital Work Instructions•

(DWI) for Quality Procedures

Poka-Yoke•

Autonomation•

Test and Inspection•

Manufacturing Execution System

BETTER SOLUTIONS.

BETTER OUTCOMES.

Alignment with BusinessObjectives

Innovation and BusinessTransformation

Solution Quality, Flexibilityand Speed

ComprehensiveCoverage

Enablers Transform Realise Enable Enablers

Inputs

Work Streams

Deliverables

Jump Start Launch Operational Excellence Strategic Solutions

Objectives

Tata Technologies Differentiator

Reduced Total Costof Ownership (TCO)

Focus on Business

Objectives and Value Drivers

Industriali ation ofsRelevant es Practice B t Process for Business

Aligned Solutions

Leveraging the Right Shorefor Delivery to Drive aFiscally Responsible’‘

Solution

Effective euse of xistingR EAssets to nsure ualityE Q

and peedy DeliveryS

ComplementaryTeaming

greements forAE -End-to nd

overageC

OUR MANUFACTURING EXECUTION SYSTEMSFRAMEWORK SOLUTION FRAMEWORK

PeopleDomain ExpertsProcess OwnersSMEs

ProcessGovernanceCommunicationQualityDelivery Metrics

InfrastructureScalable Data LineSecured ODECFailover and ClusteringVirtualisation

AlliancesSolution Partners-RockwellAutomation and GEIP

Tools

PLCAllen Bradley, Siemens,GE, Omron, Mitsubishi

SCADARockwell FT View,Siemens WinCC, GECimplicity, BeijerElectronics

Automation/DataExchange ProtocolsDeviceNet, Ethernet IP,Profibus, Profinet, Modbus, OPC

MESRA-FTPC, GE-Proficy,TTL-FM, IPMS, SAP

MES and ERPIntegrationMethodologyRFC, FTP, IntermediateDB Tables, CSV,Standard Connectors

MES SCAN

RFQ

Deliver MES KPI, Resources and Operational Targets

Opportunities of Improvements, Strategic Inputs from Identified Roadmap

Define

Plan

Execute

Verify

Business Analysis,

Definition, Design,

Development, Testing,

Deployment, Verification,

Sustain

Improvement Process

Continuous Improvement

Functional Requirement Specs, Timeline, Alignment, Value Driven Analysis

Optimised Delivery Model, Metrics Report, Improved Client Experience, Quality, Efficiency, Reduced Maintenance

Improved Time to MarketEnhanced ProductivityImproved Throughput

Our Manufacturing Execution Systems(MES) solutions help businesses respond to market changes both quickly and

effectively and help adopt production processes – in real-time. Implementing MES ensures complete visibility and

control over their shop floor operations apart from a tighter control on supply chain thus allowing the clients to take

better decisions. We develop customised line-of-business applications to meet the organisation's business objectives and

ensure quick and cost-effective implementation.

1050+ man years of ManufacturingExecution Systems (MES)

implementation experience

150 specialised resourcesin the MES practice

Key technology partners with Oracle, Rockwell

Automation and Microsoft

KEY DRIVERS TO SUCCESS

Manufacturing Execution System

ACCELERATING PROGRESS.

DRIVING RESULTS.

VALUEDELIVERED

Tata Technologies partnered with the industrial giant in India to

establish shop floor to top floor connectivity which could provide end-

to-end visibility across the in-bound and outbound enterprise supply

chain scenario.

THE COMPANYA Swedish industrial company,

manufacturing industrial tools and

equipment. It is considered as a world-

leader in providing sustainable productivity

solutions and serves customers in over 180

countries with products and services

focused on energy efficiency, safety and

ergonomics. The company has operational

centers spread across 20 locations within

India and features among the most

innovative companies around the world.

“During the integration of our supply systems with the shop floor and

supply chain, our top management required a dashboard on a web-

based application which could help them monitor the activities at the

ground level with a click of a button, either from office premises or

from external locations. The team at Tata Technologies did an

exceptional job and we have taken a unanimous decision of

implementing a similar system upgrade at another plant location too.”

-Plant Head, An Indian subsidiary of a Swedish

industrial company

CHALLENGE

The client had a non-integrated IT system which posed

challenges at the shop floor and information was present

in silos at different locations within a plant.

High Work In Progress (WIP) at sub-assembly levels,

which resulted in blocked capital

Leveraging its existing presence and small customer base

to propel sales of the new product line

Generating hype for the new product line by identifying a

healthy sales pipeline

SOLUTIONA custom-built application to provide end-to-end

manufacturing solutions inclusive of interface and

integrations with ERP, shop floor control system, third

party logistics, supermarket and finished goods yard

System deployed across two flexible assembly plants –

Make To Order (MTO) configurable products

Implementation of key functionalities notably order

management, kitting, pick list generation, JIT/JIS, e-

Kanban, ANDON system, genealogy, traceability, torque

and test data logging, digital work instructions and

finished goods yard management, pick-list and barcode

printing, real-time updates via reports, dashboards and

email

RESULTS

Sub-assembly WIP reduction from

three days to four hours

Single version of truth – Meeting

Time Reduction (MTR)

Product planning improvement by 30%

Manufacturing Execution System

©Copyright 2016 Tata Technologies. All rights reserved.

NORTH AMERICAEleven Mile Road41050 W. Novi, MI

USA48375

Tel. +1 2484261482

EUROPEThe Enterprise Centre

Coventry University Technology ParkPuma Way, Coventry, UK

CV12TTTel. +44 (0) 8443 759685

ASIA-PACIFIC 25, Rajiv Gandhi Infotech Park

Hinjawadi, PuneIndia

411057Tel. +91 20 6652 9090

Making dreams a reality since 1989.product development

ABOUT TATA TECHNOLOGIES

www.tatatechnologies.com@TataTech_News linkedin.com/company/tata-technologies

16 Global Delivery CentresDetroit - Novi, Detroit - Troy, Chicago (USA), Coventry & Bristol (UK), New Delhi, BlueRidge Pune, Hinjawadi Pune, Bengaluru & Thane (India), Bangkok (Thailand), Brasov, Craiova & Iasi (Romania), Shanghai (China) and Singapore

8,500+ Professionals

Europe, North America,Asia-Pacific

3 Regions

Tata Technologies, founded in 1989, enables ambitious

manufacturing companies to design and build better products

through engineering services outsourcing and the application of

information technology to product development and

manufacturing enterprise processes.

With over 8,500 professionals, representing 28 nationalities, Tata

Technologies focuses on the manufacturing industry - covering

every aspect of the value chain from conceptualisation,

manufacturing, aftermarket and maintenance repair overhaul

support. Tata Technologies supports clients through engineering

services outsourcing, product development, IT services and

product management solutions.

Tata Technologies serves clients in 27 countries, with a delivery

model specifically designed for engineering and IT engagements

that offers a unique blend of deep, local expertise integrated with

16 global delivery centres across Europe, North America and Asia

Pacific.