MES system and its integration with other IT systems

Concept of MES(Manufacture Execution Systems)

The MES is an evolution of the concept of CIM (Computer Integrated Manufacture) that sought to integrate the control systems and automation of production, with the use of supervisory software interconnecting through industrial data networks, PLCs (Programmable Logic Controllers) sensors and actuators. It was observed later that such information was not sufficient to assist in managing the planning and execution of the production process from business point of view. At the same time appeared a system that integrated the administrative areas of the company, known as ERP, and communicated poorly with the platforms of CIM. The MES seeks to fill the space between the automation and data collection with the ERP, with a proposal for managing the flows of productive processes to streamline the use of their resources to achieve maximum productivity and profitability. Currently, there are several proposals for standardization of MES solution, but we will focus on the ISA S95 standard.

There are differences in the objectives between the need for corporate management and what is offered by the ERP, and the needs of the production management of a manufacturing company. In general, production management needs data and information in real time and for short and medium term decisions to remove immediately occurrences of losses as well as plan and monitor the production and daily, weekly and monthly maintenance. The standard defined by ISA S95 defines terminology and models that are used to integrate with ERP systems and automation systems. This standard has been declared as standard by ANSI and is divided into the following parts:

Part 1 : Published in 2000 , contains the basic terminology and models to define the interfaces between processes and ERP management processes of production .

Part 2 : Published in 2001 , defines along with Part 1 , the contents of the interfaces between the control functions of production management and corporate .

Part 3 : Published in 2005 , provides detailed definitions of the main activities of production , maintenance, storage and quality control .

Important to note that should be established in the database of the corporate system , shared data tables , which contain access to master data records to be used by ERP and MES systems , as a means for exchanging data and information between them

Today there are other technologies that facilitate these integrations, such as SOA ( service oriented applications ) portals in integration systems, especially in ERP , which can be accessed through web services , which do not require any knowledge of the constitution or the procedures from each system in order to effectuate communications between them.


Systems Level models as ISA S95..

Regardless of the definition of ISA S95, how to access these data should be made transparent to the internal features of each system, preferably through web services calls. Some of the definitions of the first part corresponding to the levels described in the above figure are:

Level 4:

- Management and maintenance of raw materials and spare parts , and update their master record data , which should be shared with other information systems .

- Management and maintenance of energy resources.

- Managing and maintaining records of the master data required for forecasting the preventive maintenance and resources to accomplish them.

- Production Planning, based on data from available resources and scheduling planned maintenance, with constant revisions of this plan.

- Maintainability of master data records of the warehouses, for maximum accuracy of their inventories.

- Establish inventory rationalization, energy consumption, spare parts and raw material inventories to release production orders.

Level 3:

- Evaluation of relevant production data, including data definition of true costs of production.

- Management and maintenance related to production, inventory, human resources, raw materials, spare parts and energy data. Furthermore , should also be made ​​managing and maintaining data and additional functions such as the timing of production cycles , calendars holiday , human resource planning , human resources development and etc. ...

- Establishment of detailed planning and rationalization of all productive sectors , this includes some possible times of transport , maintenance and other relevant tasks in the production process .

- Monitoring of the entire production process, with functions of alarms, tracking and monitoring the flow of the production process.

- Provide functions for managing quality.

- Reserve resources to meet the production plan and warn breakdowns of equipment that require replanning of the production plan. The production orders should be made available to the productive sector through the system as well as monitoring performance.

In summary, the specifications, in general, are not very detailed, it can generate differences of interpretations, but the concepts are relevant in order to have the model that enables the management of production and its integration with other systems in the enterprise.