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MES Solution Framework
Food & Beverages Metals & Mining / Cement Life Science & Pharmaceutical Oil & Gas
Manufacturing Chemical Energy & Power Infrastructure & Utility
1
Contact: Sunil Wadhwa
Our Solutions & Services
SAP
MII
MES,
Batching
MIS, LIMS
Software
development
SCADA, DCS
PLC, Drives, Safety Systems
Instrumentation & Electrical Engineering
Manufacturing
Pharma & Life
Sciences
O & G/
Petrochemical
Energy &
Power
FMCG
Metal &
Mining
Utilities
HVAC & BMS
Chemicals
2
Contact: Sunil Wadhwa
• Comprehensive, Yet Modular Solution
• Single Integrated Plant IT Infrastructure – Easy to Maintain & Upgrade
Plant
Intelligence
Solutions -
Unique
Architecture
SAP MII
Connector
Business System–SAP/ ERP
Solution Map
MES Preparedness
MES
SAP
Integration
3
Contact: Sunil Wadhwa
• Communication enablement of Existing PLC/ CNC/ Robots/ Controller/HMI/Bar-
Code Reader/ Vision Camera/ Weigh Scale/DCS with required engineering for
connecting to MES
• Complete solution from As-IS Study to Add-on Hardware Supply, PLC/CNC/HMI/
Robot program modifications, network design, tag level engineering, mapping with
MES database, OPC enablement.. Single OPC connection for MES system
• Central Data collection from disparate PLC/control systems/Equipment pertaining
to process parameters.
• Data Acquisition as per required Speed, Scaling, Tags, etc in order to facilitate MES
• A building block for building MES solution with/without data collection & reporting
solution
MES Preparedness/OPC enablement
4
Contact: Sunil Wadhwa
• Taking data/parameters from individual CNC machines which are available in the
programming of that machines. (most essential)
• Information of currently running process and product in individual machines.
• Calculating the OEE of individual machines and complete line as well.
• All data accessible to all concern authority through wireless /LAN media
• Troubleshooting and route cause analysis to reduce the downtime
• Tracking of changes made in programming
• Verification of programming /schedule about to load next in the machine
• Automatic management of Production Batches
What it means for your Machines / Assembly Line?
5
Contact: Sunil Wadhwa
Typical System Architecture- MES preparedness
6
Contact: Sunil Wadhwa
Central OPC Server
PLC-N
Serial to Ethernet
Converter
Ethernet Network
HMI- PLC connection
Ethernet Network
Serial Network
SCADA HMI
HMI
PLC-1 PLC-2 PLC-3
PLC Add-
on card
Ethernet Network
CNC -1 to NRobots-1 To N
HMI/SCADA, Batch, PPS, Tracker
SOA&Workflow
DataMart
Control & IO
Portal(RTIP)
SAP, Oracle, Microsoft Dynamics, etc.
Historian
SharePoint,BO,Etc..
Plant Apps
Production
Tracking
Quality
Management
Efficiency
Management
Schedule
Execution
Genealogy
Traceability
Energy
Management
Environmental
Management
ManufacturingIntelligence
Manufacturing
Execution &
Performance
Management
WebSpace(ThinflexibleGUI)
Manual Work Processes
Enterprise
Resource
Planning
ERP, PLM,
SAP MII
“plant apps”
Condition-based
Maintenance
Scheduling
Troubleshooting
BusinessIntelligence
CollaborativeProductionManagement
Proficy Product / Solution Map
7
Contact: Sunil Wadhwa
OEE Summary – Downtime
Distribution
The Downtime Distribution
Dashboard displays the
total “Pkg 1” Downtime
based on Fault Code.
8
Contact: Sunil Wadhwa
OEE Summary Dashboard
An “OEE Summary Dashboard” is available for real-time display of OEE values via a web browser. This type of report
(combined with other KPI information) is ideal for use in Overview Dashboards monitored by corporate personnel.
9
Contact: Sunil Wadhwa
Our Value Proposition
• Local presence with Global experience – Global Delivery Model
• Preferred VAR and Implementation Partners
• Leading Engineering & Software Solutions provider
• Technical know-how on Latest and Legacy systems of - Major
Automation Supplier’s Siemens, Rockwell, GE-Fanuc, Emerson, ABB,
Honeywell, YBL etc
• Comprehensive knowledge and rich experience in Plant Intelligence
Solutions & Industrial Automation Technology in Level 1, 2, 3 & 4 –
SCADA/Historian/Batch/LIMS/MES/SAP-MII/Homegrown data base
• Sector Know how – Manufacturing, Factory Automation, FMCG, Pharma,
etc.
• Dedicated Solution Practice – 50+ consultants…
• Proven Project Management Model
• Rich experience in similar solution in CPG industry
10
Contact: Sunil Wadhwa
Benefit Realization on ROA & ROI
Integration of Plant Control System with MIS, MES, ERP
Productivity & OEE
Gains
Enterprise
Resource Planning
ERP, PLM
Connected
Systems – PLC,
CNC, HMI,
Robots, SCADA
& DCS
MIS – Real Time
Plant Data
Integration,
Analytics of
Mfg Processes,
Improved
Visibility of
Plant Data
Disparate & Non-
Standard
Control Systems,
No Connectivity,
No Visibility of
Plant Data & Lots
of
Bottlenecks, High
Maint Cost
ReturnonAssets&Investment###
Manufacturing
Execution, Oper
ations &
Performance
Management,
Geneology, etc.
Note: ###The data used above is only for indicative purpose based on general observations in industry. The actuals gains could be different based on real
implementation of system and nature of plant/process/ industry.
THANK YOU
12© May 2014. All trademarks and products mentioned in this presentation are properties of their respective owners.

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Plant Integration and MES Solution for Industry

  • 1. MES Solution Framework Food & Beverages Metals & Mining / Cement Life Science & Pharmaceutical Oil & Gas Manufacturing Chemical Energy & Power Infrastructure & Utility 1 Contact: Sunil Wadhwa
  • 2. Our Solutions & Services SAP MII MES, Batching MIS, LIMS Software development SCADA, DCS PLC, Drives, Safety Systems Instrumentation & Electrical Engineering Manufacturing Pharma & Life Sciences O & G/ Petrochemical Energy & Power FMCG Metal & Mining Utilities HVAC & BMS Chemicals 2 Contact: Sunil Wadhwa
  • 3. • Comprehensive, Yet Modular Solution • Single Integrated Plant IT Infrastructure – Easy to Maintain & Upgrade Plant Intelligence Solutions - Unique Architecture SAP MII Connector Business System–SAP/ ERP Solution Map MES Preparedness MES SAP Integration 3 Contact: Sunil Wadhwa
  • 4. • Communication enablement of Existing PLC/ CNC/ Robots/ Controller/HMI/Bar- Code Reader/ Vision Camera/ Weigh Scale/DCS with required engineering for connecting to MES • Complete solution from As-IS Study to Add-on Hardware Supply, PLC/CNC/HMI/ Robot program modifications, network design, tag level engineering, mapping with MES database, OPC enablement.. Single OPC connection for MES system • Central Data collection from disparate PLC/control systems/Equipment pertaining to process parameters. • Data Acquisition as per required Speed, Scaling, Tags, etc in order to facilitate MES • A building block for building MES solution with/without data collection & reporting solution MES Preparedness/OPC enablement 4 Contact: Sunil Wadhwa
  • 5. • Taking data/parameters from individual CNC machines which are available in the programming of that machines. (most essential) • Information of currently running process and product in individual machines. • Calculating the OEE of individual machines and complete line as well. • All data accessible to all concern authority through wireless /LAN media • Troubleshooting and route cause analysis to reduce the downtime • Tracking of changes made in programming • Verification of programming /schedule about to load next in the machine • Automatic management of Production Batches What it means for your Machines / Assembly Line? 5 Contact: Sunil Wadhwa
  • 6. Typical System Architecture- MES preparedness 6 Contact: Sunil Wadhwa Central OPC Server PLC-N Serial to Ethernet Converter Ethernet Network HMI- PLC connection Ethernet Network Serial Network SCADA HMI HMI PLC-1 PLC-2 PLC-3 PLC Add- on card Ethernet Network CNC -1 to NRobots-1 To N
  • 7. HMI/SCADA, Batch, PPS, Tracker SOA&Workflow DataMart Control & IO Portal(RTIP) SAP, Oracle, Microsoft Dynamics, etc. Historian SharePoint,BO,Etc.. Plant Apps Production Tracking Quality Management Efficiency Management Schedule Execution Genealogy Traceability Energy Management Environmental Management ManufacturingIntelligence Manufacturing Execution & Performance Management WebSpace(ThinflexibleGUI) Manual Work Processes Enterprise Resource Planning ERP, PLM, SAP MII “plant apps” Condition-based Maintenance Scheduling Troubleshooting BusinessIntelligence CollaborativeProductionManagement Proficy Product / Solution Map 7 Contact: Sunil Wadhwa
  • 8. OEE Summary – Downtime Distribution The Downtime Distribution Dashboard displays the total “Pkg 1” Downtime based on Fault Code. 8 Contact: Sunil Wadhwa
  • 9. OEE Summary Dashboard An “OEE Summary Dashboard” is available for real-time display of OEE values via a web browser. This type of report (combined with other KPI information) is ideal for use in Overview Dashboards monitored by corporate personnel. 9 Contact: Sunil Wadhwa
  • 10. Our Value Proposition • Local presence with Global experience – Global Delivery Model • Preferred VAR and Implementation Partners • Leading Engineering & Software Solutions provider • Technical know-how on Latest and Legacy systems of - Major Automation Supplier’s Siemens, Rockwell, GE-Fanuc, Emerson, ABB, Honeywell, YBL etc • Comprehensive knowledge and rich experience in Plant Intelligence Solutions & Industrial Automation Technology in Level 1, 2, 3 & 4 – SCADA/Historian/Batch/LIMS/MES/SAP-MII/Homegrown data base • Sector Know how – Manufacturing, Factory Automation, FMCG, Pharma, etc. • Dedicated Solution Practice – 50+ consultants… • Proven Project Management Model • Rich experience in similar solution in CPG industry 10 Contact: Sunil Wadhwa
  • 11. Benefit Realization on ROA & ROI Integration of Plant Control System with MIS, MES, ERP Productivity & OEE Gains Enterprise Resource Planning ERP, PLM Connected Systems – PLC, CNC, HMI, Robots, SCADA & DCS MIS – Real Time Plant Data Integration, Analytics of Mfg Processes, Improved Visibility of Plant Data Disparate & Non- Standard Control Systems, No Connectivity, No Visibility of Plant Data & Lots of Bottlenecks, High Maint Cost ReturnonAssets&Investment### Manufacturing Execution, Oper ations & Performance Management, Geneology, etc. Note: ###The data used above is only for indicative purpose based on general observations in industry. The actuals gains could be different based on real implementation of system and nature of plant/process/ industry.
  • 12. THANK YOU 12© May 2014. All trademarks and products mentioned in this presentation are properties of their respective owners.

Notes de l'éditeur

  1. This is carefully thought out