MES; SCADA; PLC

Why MES?
Missing link between PCS (Process Control Systems) and corporate systems (typically ERP) PCS attached to devices on factory floor
Often proprietary technologies Export data as text Often left unconnected Or managed by specialists (non-IT) Critical systems (eg: BGE) Requirement for compliance

ERP does not finish where PCS begins Invoke different competences

Manufacturing Executive Systems

Includes shopfloor instrumentation, control hardware, planning and control systems, process engineering, inventory, quality systems.

Manufacturing Execution Systems (MES),

are IT systems that manage manufacturing operations in factories. Scope includes: Management of product definitions. Includes storage, version control and exchange with other systems of master data like product production rules, bill of material, bill of resources, process set points and recipe data all focused on defining how to make a product. Management of product definitions can be part of Product lifecycle management Management of resources. Includes registration, exchange and analysis of resource information, aiming to prepare and execute production orders with resources of the right capabilities and availability. Scheduling (production processes). These activities determine production schedule as a collection of work orders to meet production requirements, typically received from Enterprise resource planning or specialized Advanced planning & scheduling systems, making optimal use of local resources.

 Dispatching production orders. Depending on the type of production processes this may include further distribution of batches, runs and work orders, issuing these to work centers and adjustment to unanticipated conditions. Execution of production orders. Although actual execution is done by Process Control Systems (PCS), an MES may perform checks on resources and inform other systems about the, progress of production processes. Collection of production data. includes collection, storage and exchange of process data, equipment status, material lot information and production logs in either a data historian or relational database. Production performance analysis. Create useful information out of the raw collected data about the current status of production, like Work In Progress (WIP) overviews, and the production performance of the past period like the Overall Equipment Effectiveness or any other Performance indicator. Production Track & Trace. Registration & retrieval of related information in order to present a complete history of lots, orders or equipment (particularly important in health related productions, e.g. pharmaceuticals)

Relationship
Corporate
production planning, scheduling

MRP II/ ERP

batch, production run reporting or completion

Planning
When/What to make Planned/standard lead times/ yields/wastes/costs

Execution
Production management/tracking - WIP, equipment, operators Production scheduling Quality control/SQC Costing Maintenance Management functions Communications, reporting

Plant
recipes process setpoints operating instructions

MES
actual process conditons, completion of process steps and operations, performance of equipment and raw material and operator actions

PLC

Robots/ AGV

Control
Ladder logic Continuous feedback PID Advanced control

DCS

ERP-MES-Control Data Flow

Planning
MPRII/ERP
Forecasting Costing Production Planning Product Definition Process Definition SOP Human Resources Inventory Management Purchasing Distribution
Product Demand BOM/Formula/Recipe/Drawing /Part Program Resources Routing/Process Labor Characteristics Inventory Status SOP, HEALTH, WORK Instructions

Execution
MES
Resource Alloc./Status Operations Scheduling Production Dispatching Document Control Data Collection/Acq. Labor Management WIP Status/Traceability Quality Management Performance Analysis Process Management Product Tracking and Genealogy Maintenance Management
Process Instructions:Recipes, Work Instructions, Part P rograms, Order Specific, Machine Utilization, Work Certification Requirements Operator Instructions:Scheduled (predictive) & Preventative Maintenance, Material Safety Instructions (documents), Machine Operation Instructions (documents) Drill Down (inquiries) Status Process Status B atch End Reports Ad Hoc Inquires Materials Analysis Events: Time/Date/Lot/Alarms Data Collected f rom Monitoring Functions: P rocess, Equipment, Environment, Labor, Material, Product Parameters

Control
Monitoring & Sensing
Process Equipment Environment Labor Material

Control
Machine Control Regulatory Control Realtime QC Advanced Process Controls

Order Status/COmpletions /Start-Due-End Resource Status/Usage Labor Status/Usage Material Status/Usage Actual BOM/Formula/Recipe/ Drawing/Part Program Actual Routing/Process Product Genealogy/Traceability /As Built Information Scrap/Waste

Operations
Process Sequencing Machine & Process Instructions Labor Instructions Human Machine Interfacing Safety Maintenance Focus: Process Decision Location: Shop Floor/Plant Floor

Focus: Customer Decision Location: Office

Focus: Product Decision Location: Factory

MESA International-White Paper

SCADA (Supervisory control and data acquisition)

Supervisory Control & Data Acquisition software gathers data in real-time to control equipment and conditions. These systems include hardware and software components to gather and present manufacturing data for quality control, inventory management and production planning.

SCADA
generally refers to industrial control systems: computer systems that monitor and control industrial, infrastructure, or facility-based processes, as described below: Industrial processes include those of manufacturing, production, power generation, fabrication, and refining, and may run in continuous, batch, repetitive, or discrete modes. Infrastructure processes may be public or private, and include water treatment and distribution, wastewater collection and treatment, oil and gas pipelines, electrical power transmission and distribution, Wind farms, civil defense siren systems, and large communication systems. Facility processes occur both in public facilities and private ones, including buildings, airports, ships, and space stations. They monitor and control HVAC, access, and energy consumption.

SCADA System usually consists of following subsystems:

A Human-Machine Interface or HMI is the apparatus which presents process data to a human operator, and through this, the human operator monitors and controls the process. A supervisory (computer) system, gathering (acquiring) data on the process and sending commands (control) to the process. Remote Terminal Units (RTUs) connecting to sensors in the process, converting sensor signals to digital data and sending digital data to the supervisory system. Programmable Logic Controller (PLCs) used as field devices because they are more economical, versatile, flexible, and configurable than specialpurpose RTUs. Communication infrastructure connecting the supervisory system to the Remote Terminal Units.

PLC: Programmable logic controller or programmable controller

is a digital computer used for automation of electromechanical processes, such as control of machinery on factory assembly lines, amusement rides, or lighting fixtures. Used in industries and machines. Unlike general-purpose computers, PLC is designed for multiple inputs and output arrangements, extended temperature ranges, immunity to electrical noise, and resistance to vibration and impact. Programs to control machine operation are typically stored in battery-backed or nonvolatile memory. A PLC is an example of a hard real time system since output results must be produced in response to input conditions within a bounded time, otherwise unintended operation will result.