Industry 4.0 Aligned MES Software towards SMART Manufacturing by Prabakar Selvam

1. Industry 4.0 Aligned MES Software
towards
SMART Manufacturing
By
Prabakar P Selvam
Founder & CEO, Cantier Systems Pte. Ltd.

2. Industry 4.0 is the current trend of automation and data exchange in
manufacturing technologies.
It includes:
• Cyber-Physical Systems
• The Internet of things (IoT)
• Cloud Computing and Big Data.
Industry 4.0 creates what has been called a "Smart Factory".
Industry 4.0

3. SMART Manufacturing is:
According to a recent white paper from MESA International,
“Smart manufacturing is the endeavor to design, deploy, connect and
manage enterprise manufacturing operations and systems that enable
proactive management of the manufacturing enterprise through
informed, timely (as close to real time as possible), in-depth decision
execution.”

4. Smarter Applications
The overall goal of smart manufacturing is to rapidly create applications that enable
collaboration between all people, systems, and assets across a value chain.
• Applications that provide just the right amount of the right information
to the right role at the right time to allow them to make the right
decision and take immediate action.
• Applications that communicate between systems driving workflows and
autonomous action.
• Applications that prevent and predict issues by applying artificial
intelligence and machine learning technology.

5. Smarter Applications
The focus of smart manufacturing, therefore, is about the availability of
information allowing timely and correct decisions to optimize
competitiveness.
The creation of a homogenous, harmonious and totally
interconnected entity is the great challenge of smart manufacturing.
In this context, MES/MOM systems constitute a fundamental base for
every smart production solution.

6. Industry 4.0 Solutions
Industry 4.0 is the current trend of automation and data exchange in manufacturing
technologies. It includes Cyber-Physical Systems, the Internet of things (IoT), Cloud Computing
and Big Data. Industry 4.0 creates what has been called a "Smart Factory".
• IIoT
• SCADA
• Cell Controller (SECS/GEM)
• Robotics
• MES
• ERP Integration
• Big Data
• Cloud

7. MES Software
“MES/MOM systems constitute a fundamental base for every smart
production solution” - MESA

8. MES Does the following:
• Provides information on the efficiency of a machine line or department to allow operators
to minimize downtime or waste
• Analyzes the need for raw material of production areas to ensure that it is available when
needed while minimizing inventory in warehouses
• Collects and processes information related to the use of raw materials in the production
cycle to allow the management system to update the stock availability and correctly the
calculate product cost
• Guarantees traceability and tractability to minimize the impact of any recall actions
• Tracks the progress of production to optimize the use of the machines/resources.

9. WIP Traceability
1. Product Configuration
• BOM
• Route (Process Flow)
• Product Spec
2. Job Order Management
3. Lot Traveller

10. Product Configuration

11. Lot Traveller

12. Equipment Maintenance 12
Production Output Summary per Product Production Output Summary per Process
Average Cycle Time (hrs) Yield Summary

13. 13

14. SPC & Data Management
• IIoT Data Collections
• Real Time Monitoring
• Auto Email Notification for Out of Controls Process
• SPC Analysis Tools

15. SPC & Data Management

16. Shinkawa1 Shinkawa2 Shinkawa3
Dage Auto Ball Shear Tester
Shinkawa1 Shinkawa2 Shinkawa3
Dage Auto Ball Shear Tester
USL
UCL
CL
LCL
LSL
1 2 3 4 5
17
18
19
20
21
22
23
USL
UCL
CL
LCL
LSL
1 2 3 4 5
17
18
19
20
21
22
23
Test FAIL
AUTO STOP
Production
Test Pass
Continue
Production
Cyber
Physical
System (CPS)
Auto Wire Bond
(Programmed Robot)
Auto Transport
(Programmed Robot)
Auto Ball Shear
(Programmed Robot)
Auto Control Chart
Evaluation
(Artificial Intelligence)
Auto Shutdown
ACTION!
PROTECT;
- Customer
- Quality
- Profits
IIOT, Cyber-Physical Systems

17. Equipment Maintenance (EMMS)
1.Equipment Maintenance Definition
2.Work Order Management
• Preventive Maintenance
• Predictive Maintenance
• Corrective Maintenance
3.Equipment Logs
4.Equipment Problem Knowledge-base
5.Spares Requirement Planning

18. EMMS – Work Order Management

19. TOWA Mold
Pot &
Plungers have
a “guard
banded” life of
1M strokes.
800K Strokes =
MES Software
Communicates
with ERP to
Order PM Spare
Parts
900K Strokes =
EMMS Auto
schedules the
PM
1M Strokes =
MES SHUTS DOWN all lot
movements from this tool
and Auto notifies
Manufacturing, Equipment
Engineering, QA and the GM
Usage Based – Predictive Maintenance

20. +
X-RM Vibration in mm/s
Predictive Maintenance
Protecting Your Assets Behind the Scenes

21. Data Collection 21
PM Schedule Compliance (%) Mean Time to Repair (minutes) Mean Time Between Failures (minutes)
Equipment Breakdowns Top Breakdown Reasons Top PM Re-schedule Reasons

22. OEE- Overall Equipment Effectiveness
oee.com
Failures
Assists
MTBA
MTBF

23. Equipment Maintenance 23
Overall Equipment Effectiveness

24. Enabler of Lean, Six Sigma & TPM
Lean Simply put, completing jobs on time using the least amount of inventory and WIP
possible.
MES Tools • Inventory
• BOM, Route,
• MRP, Factory Planning
• WIP
• Data Collection
• SPC
• EMMS
Six Sigma A six sigma process produces 3.4 defects/Million.
The DMAIC Methodology is used to drive manufacturing process towards Six Sigma.
TPM A Methodology aimed at forming a corporate culture focused on Maximizing the
Efficiency of the Overall Production systems through teaming and empowerment.
TPM Metrics: MTBF, MTBA & OEE

25. Anywhere, Any Device and at Any Place

26. MES – Key Benefits
• Control shop floor operations
• Meaningful manufacturing and engineering data
• Improved product traceability
• Reduced manufacturing costs
• Reduced manufacturing cycle time
• Better understanding of equipment utilization
• An enabler to paperless manufacturing
• Gate way to SMART Manufacturing

27. Cantier® MES (Manufacturing Execution System)
Your Gateway to SMART Manufacturing
Cantier MES is an Industry
Specific, configurable and highly
scalable software that includes
real-time Operations,
Inventory, Quality and
Maintenance Management in a
Single Application.
TM
www.cantier.com