With the rapid progress of the train era, human society has entered the information technology led the twenty-first century. This is a new era, an information technology guidelines for all times, an information technology pervasive, ubiquitous century. The advent of the information age has brought us a new life and rules of the game, only by constantly adapt to the requirements of the information society, we can have their own living place.
Similarly, the information technology are constantly changing our thinking, including our understanding of enterprise management. With the development of information technology, it brings to the enterprise management of comprehensive, revolutionary change. For the ongoing management of this information revolution, the present attempt to conduct a comprehensive characterization and generalization may be futile, made by any judge and predict is likely to be inaccurate. The only certainty is that this information revolution on the impact of management theory and practice is important and far-reaching. It is said that the future plant will be only two employees: a and a dog, who is feed the dog, but the dog is to prevent people touch the factory computer. So began a variety of management of innovation and increasing tendency to rely on information technology tools. Thus they were currently on the market: ERP, SCM, CRM, EIP, PDM and many other diversified information management software, have begun to widely used enterprise management, has also made certain management effectiveness, and gradually more management are acceptable.
But these systems are mainly yes right business management data processing and computing, mainly applied in the planning, forecasting, calculation of areas, but focus on the business management requirements of ----- the production site management and not to mention, therefore, enterprise management as the production site to operate in the black box, like so many managers also benefit virtually discounted, currently in China, Haier, Lenovo, Taiwan, Delta, Henderson and other well-known producers, started a kinds of new information management technology is the manufacturing execution system (MES), the domestic scene have said the data acquisition system. This is a set of hardware and software in one system, the following we describe the specific conduct of its.
1, first of all, we live from the production situation and problems about the management of
Marketing in the last two years from production-oriented quickly evolved into a market-oriented, competition-oriented, and thus make the production situation in the field have been great changes, the traditional on-site management has been unable to cope with this new situation, we can changes in production patterns and the extension of the problem is reduced into the following points:
(1) product life cycles
Information electronic products most representative of this phenomenon. Products replace the new force to accelerate product design, engineering and production departments increasingly close relationship between. Production units continue to face new components, new equipment, new processes and frequent engineering changes, manufacturing site needs a real-time production instruction system to effectively guide production personnel work standard, and can correct the situation quickly to produce reaction to the design and manufacturing sector, production problems in time to find new products.
(2) a small amount of various types of production
Pioneer Henry Ford Ford Motor have said in 20 years: "I can give any customer any style of car, as long as it is black. And now progress to the customers in the sales mix in the store to select from hundreds of The car to be equipped with the immediate orders to the factory, you can always know that your car has been produced to what extent. As the small diversified production patterns, on-site at any time filled with many different manufacturing work order, different in the products, components, units must have mixed line production capability, flexibility and efficiency in the day to meet different product requirements.
(3) rapid changes in the market difficult to predict
Business is war, no longer see the last large-scale formal operations, and now emphasize that the rapid strike forces, able to cope with unexpected situations around the world. Production site is to be able to cope with the fast-changing mobile Order Production patterns are difficult to predict.
(4) international competition increasingly fierce
Increasing internationalization of economic development, face to face not only domestic competition but all over the world-class product competition. In terms of production, are facing is to continuously improve product quality and reduce production costs. Good to do business over the last boss, only the production site as a black box, now under the pressure of competition this black box must be transparent, to identify any impact on the quality and cost issues, and to seek concrete measures.
2, then what is manufacturing execution system - MES
Computer applications in the manufacturing sector and the development of the computer itself and the evolution of production patterns are closely related. Past production patterns more simply, is top down (Top Down) plan types, the focus of computer applications in production planning and management (MRP-Ⅱ) and general transaction processing, and field operations management still remain in the traditional form of artificial work patterns. Even the so-called floor control functionality (Shop Floor Control - SFC), is also subject to the traditional large-scale / micro-computer and electronic technology, more information is collected, then input the batch processing capabilities provided limited.
In the factory automation (Factory Automation - FA), the past is emphasized more in the logistics automation (Material Flow Automation), such as automated production equipment, automated test equipment, automated material handling equipment and storage equipment. They did replace a lot of labor, to resolve a number of production bottlenecks, but also because of the mismatch-related operations, and did not give full play to their effectiveness, while the so-called "islands of automation," said the (Islands of Automation).
From the questions, there is a need for information flow field automation system (Frontline Data Automation) to solve, such systems are used in the factory if the manufacturing site, which we call MES-Manufacturing Execution System (MES). In Japan, they call point of production management information system (Point of Production - POP), borrowing from commercial automation can simulate the sales point (Point of Sales - POS), Japan's name is quite expressive, because either POP or POS, its spirit is the same idea is shared, and can be described as a bottom-up (Bottom Up) real-time intelligence to grasp the situation on-site management system.
MES before importing, the company MRP system and the production sites of communication between the way through man-made, so that the production site as a black box, unable to grasp the real-time accurate information. After the import MES automated flow of information in addition to providing on-site in addition, it plays a connecting function, to computer integration (Computer-IntegratedManufacturing - CIM) level. We MES three initials, not difficult to see, it MRP (Manufacturing Resource Planning) or ERP (Enterprise Resource Planning) system, the interaction between a planning system is the upper (Planning), a practical implementation of the lower System (Execution).
Third, the development of History
MES demand is more than a decade of change production patterns generated, so it's history than the MIS, MRP, CAD / CAM and so short. In advanced countries, the Duo has a professional Congshi MES's company, they are mostly from Kai source or internal requirements to the project plan manner, when, after considerable experience accumulated gradually formed an independent professional company, and its Xitong also developed to a mature standard. Usually for specific industrial production patterns, or specific functional requirements and develop a more standardized MES. (Such as the United States, Consilium, Canada's Promise is the development of IC companies are well-known plant MES vendors.) Or real-time quality control system, or site-specific functions such as scheduling manufacturers have developed such products. In addition, many companies, after many years of technical experience to develop some of the core development tool, while selling these development tools to System Integration company, on the one hand themselves to use these tools to undertake MES case.
4, MES functions
We will be on-site management is divided into four functional levels, in order:
(1) tracking (Tracking)
(2) supervisory function (Monitoring)
(3) control (Controlling)
(4) management (Management)
We have thus the following four functions of MES on the traditional way and do a comparison, in the later chapters, we will do the actual situation of several industries to further details.
4.1. Tracking
It features a full use of automatic identification technology, sensors, instruments and equipment, or online, can automatically collect on-site production information, and instructions can also be ordered through the production of various types of electronic display devices are real-time to announce the operating personnel, to achieve paperless (Paperless) level. Artificial form of traditional collection methods, through the layers of manual procedures required to reach the hands of managers.
Its disadvantages are:
(1) operation is slow, not timely, Er Shi intelligence value greatly reduced.
(2) error rate, the so-called Garbage In Garbage Out. Even lead to faulty intelligence misjudged decision-making, greater levels of influence.
(3) availability is low, if the information is manually recorded in a form, report, and not entered into the computer, the information availability is very low. The manual input of information is very limited original production only touched in passing, not through further analysis.
The MES data collection method has the following advantages:
(1) real time. At the scene while the incident immediately to electronic data processing type into the MES.
(2) accuracy. The use of electronic processing technology to remove human factors, so that the correctness of the 1% or more down to one hundred thousandth the following.
(3) a high degree of integrity and usability. The incident site computer processing, information can be combined, stored in computer databases.
4.2. Supervisory functions
Real-time control of manufacturing resources, the latest status and history, coupled with the process or operating rules, will be monitoring function. MES to keep track of the situation and to compare the standard set, such as the exception occurs immediately notify the relevant persons through the computer network address.
Specifications of the monitoring process, such as certain types of products require special materials or component specifications, which must be some of the manufacturing process, or finished products require some packaging components, which require operating personnel when the actual work or through the automatic identification technology and equipment online, it is easy to work situations that MES, and pre-set standards than to achieve real-time verification results.
Process quality monitoring, real-time quality data collection of all the scene, and different processes, quality inspection, repair, do not stop, the time zone or system products that do statistical analysis, and immediate response to the relevant units, to effect the quality of early warning. The function of the play, can significantly reduce the work site due to negligence or damage caused by re-processing products, thereby reducing the cost of direct labor and material, to effect the quality of early warning.
Production equipment, supervision, and be kept informed of the status of all major production equipment, such as abnormal in real time to provide maintenance, and flexible adjustment of production activities.
4.3. Control
Process monitoring functions have been, then it can further the process will be independent of the automated material handling in various equipment, automatic test equipment and automated production equipment line up to form a more complete automation systems, play the effect of integration. Basically, each independent automation equipment only solve the bottleneck of a production process, and this automatically before and after operation still need to meet the manpower and failed to give full play to the functions of expensive equipment. The MES and flexible manufacturing unit / system (Flexible Manufacturing Cell / System - FMC / FMS) play in this respect complementary role. Simply put, FMS is based on one or more automated production equipment for the core, such as (CNC), with a flexible peripheral device (such as fixtures, robots), allowing this manufacturing cell for the efficient implementation of greater flexibility in automatically process specifications of the manufacturing process. The MES mastered the production of the latest status (status), the process rules (rules) and regulate the production of paint system set target (goal) can be effectively integrated control of a self-independent automation equipment, to enhance the production efficiency of the whole plant.
4.4. Management
Automatic real-time information collected on site to do the scene in addition to providing supervision, control, the most important function is as a site management purposes. MES will be on-site real-time information collected, as well as supervision and control of the situation are immediately deposited in the database, not only state of the art has long-term storage of historical data, using a powerful database query, analysis, reporting capabilities, the traditional manual method can not be achieved management functions are realized in the MES also make on-site management to achieve Just-In Time (JIT) level.
V. Application
I have been involved in the development of various manufacturing MES, it is the information factory, car factory, machine factory representative case, the MES status to import around to make a note. Hope that I can read you intend to start a discussion, giving top priority to the effect.
5.1. Information Factory
The information referred to in the main board assembly plant for the computer system or assembly plant information products, such as PC, Power Supply, Monitor, Switch, Scanner, etc.. Information industry in the domestic export industry is a fast growing industry, its output has been above the other industries in China's economic development has a very important effect on the status. However, our information products is described in a variety of typical small, short life cycle, the order of production, international competition pressure product, so it apart from the external to master marketing information, internal and more to import MES, grasp of the overall information can continue to grow, the following information we process plant site features the traditional way of a comparison with the import MES.
(1) Process Card Management
Import ago: Each process in the product attached to a card, the operator can complete a process required to date, personnel, production information fill out the card in the process, the finished products before packaging, collected for future use in the maintenance check.
After implementation: each process in the product card attached to the serial number bar code, the operator can complete a process, the use of bar code input number, and production data (for example: bad code is also printed as bar codes), MES automatically incorporated into the time workstations, personnel information, card database stored procedures.
(2) Order Tracking Management System
Import ago: The head of the daily production of the form completed by the production unit to make the system input and output, staff attendance, etc., and then aggregated to calculate the system to make progress. However, rapid assembly line process, production supervisor never know the system so that the current progress.
After implementation: Each station processes need to brush card number, the computer can automatically calculate its own system so that all production units in the detailed process and the recent situation, the competent office of the computer for a whole plant for a minute before the system has led to the latest situation.
(3) products tracking management
Into the former: the characteristics of information often causes a bunch of factory defective items, items awaiting repair backlog at the scene. Free up 10 million yuan each year when the inventory cost of the products are common.
After implementation: The process of complete data card, MES traceability of each position in the latest products, order statistics, you can do so by the system, product category or on-site section of track in the product distribution.
(4) Burn-In Manager
Import ago: Burn-In of different models with different length of time, although the Burn-In Room Multi-PLC, automatic conveyor control, but still operate at the scene by the people, lack of access to information, not on the Burn-In to do effective use of limited space .
After implementation: through the MES and Burn-In Room PLC online, you can use the direct control of MES PLC, for the products of Burn-In and out of control, can effectively master the Burn-In time and space utilization.
(5) Packing supervision
Into the former: the same product for different customers in the region, need to configure different language manual, power supply and other packaging materials, but mixing production, prone to error.
After Import: packing staff immediately clear instructions on the package to avoid negligence, or further integration foolproof system may send alerts when an error immediately.
(6) Quality Monitoring and Management
Into the former: the quality of data quality by the quality control station input form, but is artificial fill, the data is limited, and complete overhaul of the information is entered in the process of card and number, very few factories entered into the computer, so mostly after consolidation quality report for the future quality improvement, but because of incomplete information, incorrect, not easy to find the real cause.
After implementation: testing repair all information from the bar code, or the computer to immediately enter the scene can be connected to the quality of signage, the quality of real-time display the latest status, and can do a full detailed statistical analysis to identify quality problems effectively.
(7) ship management
Import ago: to use artificial records are shipped serial number, to which a customer to do after-sales service, but also because of the lack of real-time matching capabilities, often in the shipment of aircraft types and quantity of error, causing no small loss.
After implementation: shipping the same time, brush outside the box serial number bar code reading can be checked immediately, such as the ship does not match the conditions, can be shipped immediately told the officer.
(8) integration of automation equipment
Import ago: information will be used for plant SMT,, AI, ATE equipment and more independent, low efficiency, device management is also poor.
After implementation: the MES and the SMT, AI integration may be the production of information automatically and equipment moving home state, and ATE integration, test data can automatically be taken.
(9) on-site materials management
Import ago: by mixing production, can not control actual production conditions, common in creating stop line shortage of material.
After implementation: MES system can keep track of all the latest order, the number of models assembled, calculated in real time on-site material conditions, to pre-made feed preparation, reduce manpower and shortage of material behavior in this regard.
(10) after-sales service
Import ago: Customer refurbished products, processes to identify its original card, to spend considerable human, have no idea when the ship, it is difficult to provide effective service.
After implementation: MES can master the complete process card data for each product and shipping time, providing customers a complete after-sales service.
5.2. Automobile plant
Looking at the coverage of the entire automotive industry should be from the upstream parts manufacturing satellite factories to car production plant as for the sale of its downstream distributors and factory maintenance, combined into a large production system. In the upper, middle and lower reaches of interlocking, close co-exist with, and between plugging this complex information, how to master the right information, with good planning and control, achieve the most efficient production of each automobile plant to adapt to the future survival and development are an essential goal.
Usually nothing more than car manufacturing processes from design, production, sales and after-sales service operating procedures. Which to expand production and sales of core; sales market led to heavy manufacturing Zeyi car manufacturing. Each car of the production process are generally connected through body welding, painting, interior, foreign assembly and retrieval of test steps to become a complete car.
Production process, the pursuit of quality and production efficiency, each stage of production must go through strict quality control testing, production performance tracking, smooth material for rigorous testing before leaving the factory do it again. In order to save manpower, material and financial resources and time, the general production are equipped with automated production equipment and precision instruments to ensure production quality and efficiency. However, the production of information management point of view, the domestic auto plants and more yet to reach the target.
5.2.1. The scene was not imported production line monitoring system
(1) Production Planning / Production Scheduling
The Engineering Center production through computer terminals query instructions.
Production plan can not be altered as a real-time response, with the actual situation of the production line.
(2) production line control
All control points, the artificial log production performance, not real-time access to production status.
Artificial production performance statistics, time-consuming, laborious, and prone to error.
Kanban performance scene manually by the manual and can not automatically display performance, and according to production plan CYCLE
TIME Displays the current number of program units, the difference between Taiwan and the number of hours.
Can not know the locations of the body and production status.
Approved car off the track, artificial judge.
(3) the reasons for stopping line management
Was not imported to use.
Stop line position to manual analysis.
(4) Less Chemicals
Part due to product manual recording, unified analysis and processing after collection, can not know in a short time due to product status, as a conversion measures.
Goods vehicles can not be less real-time control.
(5) Quality Management
Artificial collection of on-site quality.
After the analysis of artificial aggregate time-consuming, laborious, not real-time measures.
(6) JIT feed instructions
With on-site traffic, and telephone to inform the Production Vice-line, supply warehouses for materials.
Production schedule changes, can not reach the same period of logistics.
5.2.2. Imported production line monitoring system, computerized feature
(1) Production Planning / Production Scheduling
Production plan according to changes in real-time production instructions, synchronization of production.
Engineering Center in the management of the workstation, check the next three days on production planning / scheduling.
Workstations in the production schedule management, change site production planning.
(2) production line control
Automatic collection of production performance.
WIP tracking and performance automatically make records, real-time access to production status.
Automatic processing performance billboard display, indicating the current number of program units, the number of production units, the difference between Taiwan and the number of hours of such information.
Body distribution of dynamic display, track location of each body.
Approved automatic tracking down vehicles, control of production schedules, to prevent the abnormal condition.
WIP level plan provides.
Production performance of real-time return to the main computer, combined with the operation of MRP-Ⅱ.
(3) the reasons for stopping line management
Stop line to collect on-site conditions, reasons, the responsibility for the situation at that time to do countermeasures.
Automatic analysis of the reasons for stopping line.
(4) Less Chemicals
Less goods vehicle status indicators.
Car parts to be completed due to product instructions, so that goods vehicles due to a conversion in the shortest time to complete.
Real-time tracking goods vehicles less.
(5) Human Resources Management
Calculations needed for the production of various classes of human capacity, and current use of the human capacity for comparison, as the manpower deployment reference.
Human attendance data collection, with work schedules, can be used as production efficiency analysis.
(6) quality management
Collection of on-site quality conditions, real-time statistics, analysis, as reference measures to prevent recurrence, to improve quality.
Real-time feedback on site quality signage, lower defect rate, to reduce working hours dressing.
Centrally, remove the differences caused by artificial log or error.
(7) JIT feed instructions
According to Production Planning / Production Scheduling to provide feeding instructions to the same period of logistics and production smoothly.
Body on the line according to the order, with the production plan CYCLE TIME, automatic notification of the Vice-line production, supply warehouse for the material needs of the time, place and quantity.
Automotive on the "simultaneous engineering" is the plant information system based on the full development. In the automobile manufacturing, so that all relevant departments in the production before, during and after the relevant information can be effective. By 『』 production line monitoring system to collect real-time information can be provided to the dealers see-order situation, parts suppliers view the material for the use, production plant control production planning, quality, inventory and costs. The unit personnel can do the multilateral exchange of information, thereby achieving an overall depot information system, to achieve the purpose of enhancing the competitiveness of enterprises.
5.3 Machinery Factory
Machinery industry standard is often a major indicator of national industrial development, domestic machinery have been years of effort has considerable scale, but to enhance the overall management level is even more important issue, therefore, industrial upgrading In addition to other critical automation, vendor management information of the support is imperative to enhance the efficiency of a work. Including MRP, MIS getting in mature and popular, but the scene is the most inadequate provision of information, the following is mentioned several of the current situation shows.
(1) problems in products
Traditional way of mass production in the face of various forms when a small amount of demand, generated a lot of stock in the products, on-site staff and can not really grasp its size and storage location.
(2) The master production schedule
As mass production machining essentially form, emphasizing individual machine, the process of production efficiency, ignoring the overall balance (Line-Balance), the same time, health management personnel of the Follow-Up to the very difficult to be understood machining process of the production schedule.
(3) high rate of poor quality
Between the quality of machining products do not effectively monitor the early warning issue or foolproof measures, then the whole batch of testing often lead to great internal cost back losses.
(4) Equipment Jia perturbed problems
Jia moving domestic industry equipment concepts and Toyota-style management have great differences, the former high Jia blindly emphasized dynamic rate, the latter were mainly with the actual demand. Chu Ci different basic concepts, the domestic industry's general lack of the concept and practice of TPM.
(5) equipment integration issues
Automatic promotion can be said that industry is a smooth upgrade key, therefore, in order to make equipment capacity to effectively and increase their use Tanxing, while avoiding the formation or improvement of automatic arc island phenomenon, this device integrates the problem is domestic great need to strengthen the industry and efforts.
In response to these instructions, we can clearly understand the information field the importance of quick response, but in view of the mainland China in the MES has sufficient experience of the extreme lack of professional firms, thus far only imported machinery factory MES in Iron and Mechanical ,....... and a few other manufacturers. They have a very good performance. Because, MES functionality provided not only can solve the above problem, there are other important functions, are listed below:
(1) full line Overview
Real-time monitoring the status of all machinery and equipment.
Automatic warning stop line, slow down or behind schedule (and DownLoad the SchdDATA comparison) of the workstation machine.
Automatic detection system communication.
Real-time display production line to make the current processing system, piece number, output, number and status of non-performing.
(2) Equipment Integration
Through the Internet connection, the effective integration of each machine's processing procedures and computer programs to play a key role in transmission. To DownLoad (→ production of computer equipment) and UpLoad (→ computer equipment) to improve the processing efficiency equipment.
(3) Equipment Jia Activity Status
Dynamic monitoring equipment home
House moving equipment biographical inquiry
House moving equipment efficiency analysis
(4) scheduling management
Downloaded from the scheduling system (or manually enter) the date of the scheduled production plan.
Password control of scheduling using data maintenance functions.
Real-time check of each order to invest time, completion time.
Abnormal working single query (behind schedule, should be put not into. Shall be completed not completed, engineering changes, inserting, ..)
(5) progress control,
Real-time master the actual progress of work orders and the progress made with the booking difference comparison.
Real-time control of all process units at present to be processed and processing of products.
Real-time processing to acquire all the progress of the current products.
(6) quality control
Real-time statistics to make the system non-performing rate of the number of defective products.
Real-time statistics and bad reasons for bad behavior distribution (ParetoChart).
Do not mix the various layers (work orders, product, date, ..) the quality of state inquiries.
(7) Exception Management
Records online all abnormal conditions, such as: anomalies, abnormal reason, time of occurrence, duration, disposal methods and statements.
ParetoChart statistical anomaly data.
6 |, benefit assessment
We present a mechanical plant, for example, a processing time of stay in the factory object which, according to statistics, only about 5% of the time is really spent on object processing, while the rest of the time was consumed in the retention warehouse, waiting for processing, handling, so the above test. If the factory owners bought a expensive CNC equipment, only 5% of the time it cut a little time, but as a result of a set of good and effective implementation of the MES, the potential benefits of space it is that 95% of man by negligence. However, employers are generally willing to spend money on purchase the production equipment, immediacy, but stingy on the management of indirect investment in equipment, the key lies in the lack of modern management concepts of the boss, only about ships and armament of the physical investment, and can not understanding of good management system, equipment can bring greater benefits.
As for the benefits of MES can be divided into tangible benefits and intangible benefits of two categories:
Tangible benefits:
Precise control of production conditions, enhance the delivery accuracy reached with the production and marketing.
Lies in the number of correct products, and defective items of the track, reduce product cost.
To track the serial number bar code to collect complete information, improve product quality after-sales service.
Timely response to quality problems, tracing the historical quality, improve product quality.
Significantly reduced on-site form operations and increase the productivity of field management staff.
Fully master the tools, equipment usage, make efficient use of manufacturing resources.
Intangible benefits:
Improve the quality of the image of enterprises to obtain customer confidence.
Can quickly set the correct production decision.
Enhance the competitiveness of companies.
Following the implementation of MES test after the company's benefits and costs can be analyzed to make a comparison:
Scope: System assembly line, shipping
Function: Production status management, monitoring, storage, shipping management, data collection and quality analysis
Investment costs: MES application software 1.8 million
Hardware 1.5 million MES
MES staff pay 1.4 million
Computer consumables per year (report, tape, disk, bar codes on paper .... and so on) 500 000
The operating status of the company:
Annual sales: 300 million
Semi-finished inventory amount: 40 million, the holding cost rate of 20%
Direct labor cost per month: 1,000,000
Indirect labor costs per month: 2,000,000
With the cost and operational information, the following four goals on an analysis and calculation of the cost-effectiveness, detailed instructions.
(1) increase sales and customer service standards
If you use the MES, shipping and application of bar code technology production site, the information is transmitted real-time sales staff and decision makers, accurately grasp the status of orders for and production, making higher quality on-time delivery and improve service quality and marketing competitiveness, is expected to profit increased by 1%:
Annual sales: 300 million, earnings increased by 1%: 300 000 000 X1% = 300 万
(2) reducing direct labor costs
As the MES implementation, direct labor stoppage time to be material, smooth workflow, production bottlenecks due to transfer to decision makers in real time, be resolved. Equipment readiness and the duration, resulting in a number of benefits:
Reduce direct labor costs 3%; monthly direct labor cost = 1000000
1000000 X3% X12 (months) = 360 000
Reduce indirect labor costs:
Indirect staff include production line foreman, managers, health management and property management planning, engineering and testing unit personnel, because of the MES of the integrated data, you can save a lot of data collection and processing time; and can be traced back over the past product history and no trend, application of sufficient time to analyze and solve problems rather than deal with the problem, thereby increasing their productivity, estimated benefits are as follows:
Expected to enhance the productivity of indirect workers 10%; monthly indirect labor cost = 2000000
2,000,000 X10% X12 (on) = 2.4 million
(3) reduce inventory costs
Inventory investment areas, usually where companies most in need of liquidity for most of the manufacturing industry, it is also the implementation of the MES are most likely to bring the greatest benefits of the Department. As the improvement of production operations, making production time and reduce the accumulation of semi-finished product line; and into the shipping and inventory management can always reflect the correct number of product inventory, storage time, and out of the number of records shipped to customers for product quality control (storage time is too long) sticker control and efficiency of shipping finished products are of great help: semi-finished goods inventory is expected to reduce the cost of 15%
40 million X15% X15% (holding cost rate) = 900,000
Costs and benefits in accordance with the above comparison, the first year costs and benefits are as follows:
Cost: 5.2 million
Benefits: 6660000
Net profit: 6.66 million -520 million = 1.46 million
Promote the integration of site information systems to enable enterprises towards CIM, easy to achieve the following four objectives.
Increase sales and service standards
Increase manufacturing productivity
Decrease in inventory levels
Improve management decision-making capacity
7, how to build a successful MES
MES key technologies of 发展 had passed to the very mature stage, to develop an MES in terms of the production technology, not a problem, the difficulty is how the system functions Guige out, and how to successfully Di Shi Yong MES to perform its functions. The author for a number of years required for manufacturers to develop their projects MES, the difficulties encountered can be divided into the following:
(1) plant itself is not a complete system, personnel mobility, organizational change is also large, the former set of specifications, production is complete, change the responsible officer, the specifications also change.
(2) MES in just getting started, the industry is still a lack of successful examples, its not a correct understanding of the concept and the implementation of confidence and succeed.
(3) the nature of mostly small amount of plant diversity, order-type mode of production, the scene more chaotic, often exceptions, work on the more difficult to meet.
(4) to achieve accurate real-time monitoring and management capabilities required to fully co-site work and, in general, operators engaged in production, its really difficult to enter the information requested. General MIS or MRP system is the online multi-batch operation, rather than realtime operation, implementation more flexible.
(5) MES-site first line managers (such as the foreman) had no significant advantage over the contrary, transparency of power because of the feeling of being deprived.
(6) people used to use a pen to record, more accustomed to paperless electronic operation.
(7) for MES with more emphasis on realtime data collection, monitoring and control applications than general data processing system, its technology more difficult, must have professional experience in computer system technology was sufficient competent. For the user, the system includes on-site real-time operation of the software, hardware, maintenance is also more difficult.
For the above problems, to be able to successfully implement MES should note the following:
(1) superior determination concern
这一点是任何计算机系统推行最重要的一点，尤其是MES涉及的组织层面较为广泛，上级除了要有做的决心，更要有实际的关切，让各有关人员感受到其对MES的重视，上行下效才能成功。
(2)完善的教育训练
前面提到诸多问题，例如没有正确观念、信心不够、现场人员排斥心理等须经由良好的沟通，使他们了解MES的重要性及如何使用MES成为有效管理工具。
(3)由浅而深,由线而面
MES涵盖很广，先找一能立竿见影的部份导入，使用成功是最好的教育推广方式。
(4)简化现场资料输入步骤
在系统设计上需尽量简化现场资料输入的步骤，并能立即处理,响应输入者正确与否的讯息。弹性配合现场作业的变异，能方便地将生产实际状况实时正确完整的输入系统中。
(5)系统稳定性及容错性
当系统功能包含现场制程监控时,使用者对此系统依存度愈高,对此系统的稳定性,容错性(Fault To lerance)要求也愈高,是对设计者一大考验。
(6)相关作业配合
例如条形码卷标、表格的设计印制,与MRP系统制合,须考虑周到。
(7)贯彻执行力
贯彻执行力,要求各阶层各部门确实将此系统做为管理作业上的重要工具,彼此互相督促,施予正面的压力。