NOMBRE: Milton Fonseca

FECHA: 06 de Agosto del 2015

NRC: 2119

CONTROL DE LA CALIDAD
INDUSTRIAL
MANUFACTURING
EXECUTION SYSTEMS
(MES)

DEFINITION
A manufacturing execution system (MES) is a control system for managing and monitoring work-in-process on a factory floor. An
MES keeps track of all manufacturing information in real time, receiving up-to-the-minute data from robots, machine monitors and
employees. Although manufacturing execution systems used to operate as self-contained systems, they are increasingly being integrated with
enterprise resource planning (ERP) software suites. The goal of a manufacturing execution system is to
improve productivity and reduce cycle-time, the total time to produce an order. By integrating an MES
with ERP software, factory managers can be proactive about ensuring the delivery of quality products in a
timely, cost-effective manner. (Rouse, 2012)
Manufacturing Execution Systems create flawless manufacturing processes and provide realtime feedback of requirement changes, and provide information at a single source. Other benefits from
successful MES implementation might include:
Reduced waste, re-work and scrap, including quicker setup times
More accurate capture of cost-information (e.g. labor, scrap, downtime, and tooling)
Increased uptime
Incorporate Paperless Workflow Activities
Reduced inventory, through the eradication of just-in-case inventory

Figure 1MES Components

CASE STUDY: MES - Manufacturing Execution Systems support LEAN Manufacturing empowering shop floor personnel
to take real-time decisions.
For Fast Moving Consumer Goods (FMCG) manufacturers, in particular within the food &
beverages, beauty, pharmaceutical and industrial sectors, margins continue to be under increasing
pressure. Continued price increases in raw materials, energy and personnel cost can only partially be
passed on, as consumers are becoming more cost conscious. The supplies of low cost, discounted or
cheaper trade products make it more difficult for brand manufacturers to survive under the current
Figure 2OEE - Loss visualization
market conditions. Hence, in order to maintain or grow profitability and fulfil shareholder
value expectations, the bigger portion of these increases has to be absorbed internally and
counterbalanced by efficiency improvements. This case study describes the benefits of a
strategic implementation of software packages like Manufacturing Execution Systems
(MES) to effectively reduce cost, and specifically minimise production losses in
downtimes, quality and speed. One of those MES products on the market is Factory MES,
formerly known as CDCFactory MOM, created by the US company APTEAN. It is
designed to transform manufacturing performance by empowering people to make realtime actionable decisions. By standardizing the best practices of lean manufacturing, OEE
(Overall Equipment Effectiveness) and Continuous Improvement, Factory MES provides a
real-time framework that integrates scheduling, operations, quality and maintenance. As
the system is an out-of-the-box system, which is tailored and configured to each
customers need FBC was engaged to implement CDCFactory for the German Figure 3Performance of Home page
headquartered Intersnack Group in their 15 plants across Europe.
Usually, after 6-8 weeks after Go-Live the database provides enough usable data to start looking for the first cost saving
opportunities and benefits of the system. Applying a drill down analysis approach and using 6 Sigma and Lean tools, combined with
facilitated Pareto and/or CEDAC exercises, the most impactful improvement arena is downtime or utilisation loss reduction. 6 weeks
representative data can easily be extrapolated to reflect annual losses, in particular when there are repetitive stop times that happen several
times per shift, in all shifts and every week. Assuming a minute downtime in the packaging departments costs the enterprise at least 1.00
EUR each, this has lead to a significant savings potential. FBC Ltd was able to help identify savings opportunities between EUR 30k and 80k
per plant during 1 weeks analysis. Across the 15 plants this alone represented savings in excess of EUR 600k. We have witnessed significant
OEE improvements and the workforce embracing ownership of their performance. These successful implementations have established a
standard OEE platform across the various sites on which further decisions to move towards Operational Excellence can be based. (ForesterBusiness-Consulting, 2011)
BIBLIOGRAFIA
Forester-Business-Consulting. (2011). MES - Manufacturing Execution Systems support LEAN Manufacturing
empowering shop floor personnel to take real-time decisions. Retrieved Agosto 05, 2015, from http://fbcltd.com/Case%20study_6.pdf

Rouse, M. (2012). Manufacturing execution system (MES). Retrieved Agosto 05, 2015, from
http://searchmanufacturingerp.techtarget.com/definition/manufacturing-execution-system-MES