MES Implementation in a Defense Industry Company CON2874
30.09.2014
MES Implementation in Roketsan
Ferruh Emre AytacMES Project ManagerUnit HeadProduction Planning Dept.
Efe Can OkumusMES Project CoordinatorEngineerProduction Planning Dept.
Table of Content
1. About Roketsan
2. Oracle Footprint at Roketsan
3. Purpose and Scope of MES Project
4. Challenges in Implementation
5. Developed Applications
6. Project Calendar
7. Project Facts and Achievements
8. Future Projects
3
General Information
About Roketsan
4
General Information
• Founded in 1988
• One of the Leading Defense Industry Firms in Turkey
• Specialized in Designing and Producing Rockets and Missiles
• 1850 Employees including 950 Engineers
• Two facilities:
– 5,700,000 m2 Open Area
– 80,000 m2 Closed Area
About Roketsan
5
Mission
• To serve in the national defense with our rocket and
missile systems
• To contribute to the technological infrastructure of
our country with our products
About Roketsan
6
Vision
To become the leading establishment of our country with our rocket
and missile systems, from the depts of the seas to the heights of the
sky; to be placed among the first 50 companies which direct the global
market with their sales volumes and missile technologies, by means of
our own original products and advanced technologies
About Roketsan
7
Capabilities
• Design and Development of Rocket - Missile & Weapon Systems
• Technology Development
• Production and Test Technologies
– Rocket / Missile Integration
– Composite Solid Propellant & Explosive Production
– Precision, Plastic and Composite Part Production
– Environmental, Static Firing and Flight Tests
About Roketsan
8
Products
About Roketsan
9
Milestones
Oracle Footprint at Roketsan
10
• Oracle EBS 11.0.3 Implementation Project (May 2000 – Mar 2001)
• 11.5.9 Upgrade Project (Sep 2004 – Dec 2004)
• R12 Implementation Project (Aug 2012 – Dec 2012)
• MES – Paperless Production Implementation Project (Dec at 2012 –
Feb 2014)
General Info
Oracle Footprint at Roketsan
11
• Oracle 12.1.3 is being used now
• In 2014 (projection),
– 7200 Job Orders
– 430,000 Move Transactions
– 600,000 Material Transactions
– 1,500,000 Clock In
Modules
Oracle Footprint at Roketsan
12
• Discrete Manufacturing
• Quality
• ASCP
• Financials
• Purchasing
• Engineering
• Human Resources Man.
• Enterprise Asset Man.
• Project Management
• Primavera
• Hyperion
• MES
Purpose of the Project
Purpose and Scope of the Project
13
• Redesigning all Production Processes
• Adaptation of all Production Processes to ERP
• Monitoring Production Instantaneously
• Collection of Manufacturing and Quality Data
• Using Statistical Process Control Methods
• Standardization of Reports
• Minimizing Human Faults
Scope of the Project
Purpose and Scope of the Project
14
• All (58) Shop Floors in Roketsan
• All (1442) Stakeholders in Production System
• All Projects Carried Out in Roketsan
• All Production Documents and Processes
• Configuration and Change Management
Challenges In Implementation
15
• First Implementation in Turkey
• 25 years corporate culture
• Process Variety
• Product and Project Variety
• Project Scope
• Size of the Project Team
• Energetic Area
Main Changes with MES
• Monitoring Production Offline with
5 Employees
• Limited Data about Employee and
Equipment Utilization
• Hard to Prepare Genealogy Reports
Using Hard Copy Travelers
16
After
• Monitoring Production Online Using
MES
• Online Data about Employee and
Equipment Utilization
• Easy to Reach Genealogy Reports
on the System
Before
Main Changes with MES
• Monitoring Production Offline with
5 Employees
• Limited Data about Employee and
Equipment Utilization
• Hard to Prepare Genealogy Reports
Using Hard Copy Travelers
17
• Monitoring Production Online
Using MES
• Online Data about Employee and
Equipment Utilization
• Easy to Reach Genealogy Reports
on the System
Before After
Main Changes with MES
• Monitoring Production Offline with
5 Employees
• Limited Data about Employee and
Equipment Utilization
• Hard to Prepare Genealogy Reports
Using Hard Copy Travelers
18
• Monitoring Production Online Using
MES
• Online Data about Employee and
Equipment Utilization
• Easy to Reach Genealogy Reports
on the System
Before After
Main Changes with MES
• Monitoring Production Offline with
5 Employees
• Limited Data about Employee and
Equipment Utilization
• Hard to Prepare Genealogy Reports
Using Hard Copy Travelers
19
• Monitoring Production Online Using
MES
• Online Data about Employee and
Equipment Utilization
• Easy to Reach Genealogy Reports
on the System
Before After
Main Changes with MES
• Monitoring Production Offline with
5 Employees
• Limited Data about Employee and
Equipment Utilization
• Hard to Prepare Genealogy Reports
Using Hard Copy Travelers
20
Before
• Monitoring Production Online Using
MES
• Online Data about Employee and
Equipment Utilization
• Easy to Reach Genealogy Reports
on the System
After
Main Changes with MES
• Monitoring Production Offline with
5 Employees
• Limited Data about Employee and
Equipment Utilization
• Hard to Prepare Genealogy Reports
Using Hard Copy Travelers
21
• Monitoring Production Online Using
MES
• Online Data about Employee and
Equipment Utilization
• Easy to Reach Genealogy Reports
on the System
Before After
Developed Applications
22
• 20 new screens and extensions
• Using Oracle Forms, OAF, ADF, WCC and WorkflowPersonalizations & Extensions Routings ECO Collection Plans MES Operator MES Supervisor ...
New Screens Technician’s Cockpit Document Management Conformity Assesment MES Live Broadcast XML Reports with QR Code ...
Change Management for Routings
Personalizations & Extensions
23
Integration of Routings with WCC for document attachment
Personalized MES Operator Screen
Personalizations & Extensions
24
Fields hidden, reordered and added
Extended Backflush Components Screen
Personalizations & Extensions
25
Various validations added into buttons
Technician’s Cockpit
New Screens
26
Document Management - Before
New Screens
27
Job Traveler Before MES
Document Management - After
New Screens
28
XML Publisher based Job Traveler
Document Management - Before
New Screens
29
Discrepancy Report Before MES
Document Management - After
New Screens
30
Discrepancy Report After MES
MES Live Broadcast - MESSI
New Screens
31
Project Calendar
32
Project Facts
33
• 20 new screens and extensions
• 9 new XML Reports
• 70 Project Members
• 1450 Project Stakeholders
• 37 Training Sessions
• 20,000 man-hour direct labor (Roketsan)
• 101 day consultancy
Achievements
34
• Biggest IT Project in Roketsan
• ERP usage capability for technicians
• Additional 2.1 million ERP
transactions/year (520% increase)
• 7/24 Serving IT Infrastructure
• Multiple Database
• Redesign and Simplification of Production
Processes
• Instantaneous Traceability
• Easily Accessible and Analyzable Data
• Standard Reports for Various Level of
Management
• 2.8% Decrease in Production Labor Cost
MES Workstation
35
Future Projects
36
• MES & PLM (Product Lifecycle Management) Integration
• ASCP (Advanced Supply Chain Planning)
• BI APPS (Business Intelligence Applications)
• MSCA (Mobile Supply Chain Applications)
• Shop Floor Simulation
Questions and Answers
37
Thank you for listening