Manufacturing execution systems (MES) are computerized systems used in manufacturing, to track and document the transformation of raw materials to finished goods. MES can provide the right information at the right time and show the manufacturing decision maker “how the current conditions on the plant floor can be optimized to improve production output.”MES work in real time to enable the control of multiple elements of the production process (e.g. inputs, personnel, machines and support services).

MES may operate across multiple function areas, for example: management of product definitions across the product life-cycle, resource scheduling, order execution and dispatch, production analysis and downtime management for Overall Equipment Effectiveness (OEE), Product Quality, or materials track and trace. MES creates the “as-built” record, capturing the data, processes and outcomes of the manufacturing process. This can be especially important in regulated industries, such as food and beverage or pharmaceutical, where documentation and proof of processes, events and actions may be required.

The idea of MES might be seen as an intermediate step between, on the one hand, an Enterprise Resource Planning (ERP) system, and a Supervisory Control and Data Acquisition (SCADA) or process control system on the other; although historically, exact boundaries have fluctuated. 

Benefits

“Manufacturing Execution Systems help create flawless manufacturing processes and provide real-time 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

Plant model establishment

  •  Physical Model – Plant Real Diagram depicting the equipment and others
  • Logic Model – Business Flow

 Production Process Monitoring 

  • Real Time Production Process
  • Power Generation Schedule
  • Fuel and Water Consumption
  • Alarm Management

Production Management 

  • Production Plan for the Power Generation
  • Plan vs Actual Analysis
  • Production Optimisation

 Equipment Management 

  • Asset Management
  • Operation Mapping of the Asset
  • Equipment Maintenance like Breakdown, PM and Other Maintenance
  • Shutdown Planning
  • Safety Permit Management
  • Equipment Running Analysis
  • OEE of the Plant, Area and Equipment-Wise
  • MTBF, MTTR and Why-Why Diagram Mapping

Equipment Status Monitoring 

  • Status Monitoring
  • Key Parameter Monitoring for the System Health
  • Equipment Safety
  • Efficiency and Performance Mapping of the Assets
  • Asset Life Cycle Cost Calculation

Quality Mapping System 

  • Lab Integration of the System Health like the Water Analysis, Fuel Analysis and Bed Ash, Bottom Ash Analysis.
  • Power Quality Parameters
  • Auto Inspect for the Spare Dimensional Check

 Spare Parts Management 

  • Requirement Management
  • Planning Management
  • Inventory Management with the TOC Concepts
  • Consumption Analysis

 Material Management 

  • Material Consumption and Conversion Efficiency
  • Fuel to Steam Ratio vs Benchmark

 Energy Management 

  • Energy Consumption Area Wise
  • SEC Mapping of the Process Based

 Safety Management 

  • Safety Check Assessment
  • Incident Management System
  • Environment Support System – AQM

 Dashboard and Reporting

 System Safety 

  • Storage of the Data by the Raid5 Technology
  • Periodic Data Backup Automatic
  • Disaster Recovery System
  • Rights Management
  • System Log Safety Record
  • Firewall and Virus isolation measure.