MANUFACTURING EXECUTION SYSTEM
Manufacturing Execution System and Laboratory Information Management System development
ERPMANUFACTURINGSAP
PROJECT
DESCRIPTION
MES and LIMS system were created for the tobacco factory, which is part of the international company included in the Global TOP 3.
The system is implemented and used at all stages of the production cycle, from the materials and ingredients feeding to the finished goods accounting and moving. An integration with the existing ERP WMS and SCADA systems, that allows to:
- Provide operational and analytical information to managers of different levels about the processes’ status and efficiency.
- Operate by production processes more efficiently using Lean manufacturing, 6-Sigma, and SPC methods.
- Automate the data collection and processing with other systems integration and so to minimize the waste of time for data input, errors sick, and correction.
- Have fast and full analytical reports with KPIs' monitoring, "bottlenecks" identifying and, based on trends, generate efficiency improvement plans.
BUSINESS
CONTEXT
Project timeline: STRICT
Selection process: TENDER
In 2009, the general strategy of the company was to implement the highest standards of process performance and quality assurance in all factories around the world. As a result, the management relied on increasing the level of automation in the processing and distribution of information in production, thereby increasing economic efficiency through instant KPI assessment and the rapid identification and elimination of negative factors.
Within specific indicators it means To:
- Improve OEE (Overall Equipment Efficiency)
- Increase Labor Productivity of the staff
- Reduction of Waste and Rejection
- Increase the Quality of Finished Goods
- Improve Forecasting Accuracy of the expected results
- Increase Profitability through the Manufacturing Cost Reduction
TECH
CONTEXT
Our task was to design and implement a unique system that unites the following main features:
- data exchange with/between different systems (bridge/crossroads of information streams);
- several interconnected algorithms of complex calculations;
- working fast and fail-safe with maximum avoiding human faults factor;
- hierarchy users access rights according to the workplace and segregation of duties/powers;
- provide the ability to access the required information to employees where this access was limited due to financial reasons (like SAP account licenses).
Additional requirements:
- Cover existing blind spots: material movements on the shop floor, tobacco blend preparation and transportation to cigarette lines, semi-finished products (filter rods) production, work-in-progress accounting, etc.
- Ensure system agility and the possibility of further scalability for the development of the functionality.
- User interface: intelligible, friendly, and customizable.
- Reliably integration with SAP, SCADAs, FGaccounting, and some other accounting, measurement, and control systems.
- Ensure SLA IT-support fulfillment on a 24*7 level.
- Provide full tech documentation to the system and backups of it.
- Comply to standard ISO 9001:2015 Quality Management System.
- Priority to Microsoft products.
OUTCOMES
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Operations
Efficiency
Efficiency
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Labor
Productivity
Productivity
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Quality
Index
Index
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Waste &
Rejects
Rejects
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Manufacturing
Costs
Costs
- Algorithm that collects and processes 35+ product parameters (e.g. tobacco blends and cigarettes’ physical and chemical characteristics) as well as 20+ technical and technological metrics (e.g. production cycle time, equipment shutdowns, recipe ingredients compliance control, treatment regimes data, work orders execution status, etc.).
- Collection of the FG condition status data in the warehouse, quality check, and confirmation for further dispatch to clients.
- Personnel access to production processes control through the online equipment monitoring system in the workshops.
- Visual/sound alarm system setup
- Tobacco blends feeder control (the correct blend to the right line).
- Quality indices online calculation algorithm that sets business rules of the stepwise system for complex indicators monitoring.
- Analysis of the efficiency of the equipment used in production in terms of the volume of output, the adjustments and changeovers durations, as well the source and reason for the shutdown, provision of the corresponding analytical reports.
- Production lines' status visualization on monitors and the ability to operate it via a control panel.
- Ability to administer shopfloor personnel both at the level of the entire system (timesheet) and for individual modules (workplaces of brigade members).