Process Control Re-think with MES Software Technology

The most successful manufacturing companies develop a culture of full-accountability in their

operations where it matters the most, on the plant floor. It is the physical assembly line after-all where
the complex dance of human and machine takes place to turn individual parts into “products”. Gone are
the days of assembly line management and process control where software does not play a major role
in achieving this goal; it is now essential and the latest manufacturing execution system (MES)
technologies afford any manufacturer regardless of size the means to improve product quality while
optimizing cycle time.

Re-thinking the way you control your assembly line processes means evolving into the new
methodology of manufacturing operations management (MOM) and error-proofing that ties together all
branches of the complicated world that is the plant floor, into a command center that is a configurable
solution manufacturers can access from the cloud. By using software, the manufacturer is enabled
by knowledge; i.e. raw data that is transformed visually into meaningful reports manufacturers
use to improve their business.

MES/MOM software is the tool necessary to accomplish the highest standard of quality control, which is
only possible by managing the human and machine interactions with the products and their timing. The
process control strategy becomes tangible when it is clearly represented in easy to navigate and use
websites that let you create, configure, monitor, control and report on every single process step. No
matter how complicated the product you are making the solution is flexible and scalable to handle an
unlimited number of processes. The MES/MOM software critiques every input and output; each activity
is recorded for instant feedback, or real time reports that quantify how you are performing against the
manufacturing goals you set. MES/MOM allows manufacturers to quickly and accurately determine
key performance indicators (KPI) including Overall equipment effectiveness (OEE) by closely
monitoring and adjusting cycle time and Takt time, versus your production goal and work time
scheduling.

MES/MOM software like PINpoint Information System’s MES for example is designed to error-proof
assembly line operations and optimize cycle time by controlling all assembly line processes.
Monitoring and verifying the success of every process step only leads to the manufacturing of
quality products with zero defects, finished on-time. Figure 1 shows a screenshot of the MES
system’s assembly line worker user interface or touchscreen for a product fastening operation. This
example shows the user was instructed to perform 10 fastening operations (rundowns) within the
systems’ pre-configured parameters of torque at 6.00Nm and angle at 6°. The history of process steps
the line worker performed are shown as lines 33, 34, 35, 36, and 37.

Figure 1: Assembly line worker user interface/touchscreen for fastening operations

In steps 33 and 34 the worker performed a successful fastener or bolt rundown as indicated by the
result of torque at 6.00Nm and angle at 6°. Green checkmarks and red X’s also signify the DC tool
controller’s measurement versus the MES system’s additional verification of that measurement.
Ultimately, the MES system is the final authority on whether the process step passes or fails. On line 33
you can see the fastening operation passed, even though the controller reported an error or no
measurement; versus line 37 where the controller passed the process step in err, and hence the MES
failed it sensing that torque was too low at 4.00Nm and angle was too low at 4°.

Having passed process steps 33 and 34 we then see step 35 was not successful (as shown with the
system reporting an over-torque at 20.00Nm and a high angle tolerance of 20°). Given the result of over
torque and high angle the MES system failed the operation and locked out the tool. The worker’s next
instruction and recorded process step was to attempt to reverse the fastener or bolt (step 36), and then
try the rundown again in step 37 (which the MES did not pass). As the assembly line worker progresses
in their daily activities, all the data generated by the worker and devices is recorded in the server
database for at-a-glance metrics reporting; which is also accessible from this touchscreen as indicated
by the ‘graph icon’ buttons in the right most column.
MES/MOM software empowers manufacturers to turn their product assembly plans into
measurable actions on the plant floor. It enables manufacturers to re-think the way they physically
control the assembly line by creating a closed-loop of accountability on the plant floor, i.e. by monitoring
and controlling every single process step performed in the making of the finished product. Only with
this high level of process step and cycle time critique can a manufacturer ensure total error-
proofing with maximized product quality and improved manufacturing efficiency. It is the
physical process step activities by human and machine that ultimately make a finished product;
therefore, any manufacturer that fool proof’s their assembly line activities is guaranteed improved
product quality and manufacturing efficiency.

MES/MOM SYSTEM SOFTWARE

PINpoint Information System’s manufacturing execution system (MES) / manufacturing operations

management (MOM) software is meticulously designed and tested to ‘Information Technology
Infrastructure Library’ (ITIL) standards before any official version release. Their MES/MOM and Andon
communications products have been developed since 1997 and continue to be evolved and pushed-
forward by their customers.

Thoroughly proven the software is in use daily around the World in multiple languages by leading
manufacturers. Headquartered in Burlington, Ontario, PINpoint services industry internationally from
their offices in Canada, the United States, and China. For more information, please call: +1 (905) 639-
8787, email: sales@pinpointinfo.com or visit: http://pinpointinfo.com/

RELATED LINKS

See the “Why PINpoint?” prezi here:

https://prezi.com/adp9dhp3vgn0/why-pinpoint-manufacturing-execution-system-mes-manufacturing-
operations-management-mom-solutions/

MES Systems:
http://pinpointinfo.com/mes-systems/

Andon Communications Software:

http://pinpointinfo.com/andon-3d/
Author:

Anthony Borges

Biography:

Anthony offers over a decade of manufacturing optimization knowledge, with an aptitude for solving
problems which increase manufacturing efficiency. He has successfully provided solutions to various
multinational manufacturers involving the latest technology in sensors, laser (detection, measurement,
welding, cutting, and marking systems), PLC, machine vision, microscope, and software solutions.

Keywords:

manufacturing execution system, manufacturing operations management, MES system, andon, andon
system, andon software, error-proofing, lean manufacturing, six sigma, paperless manufacturing,
continuous improvement, quality control, process control, smart factory, industry 4.0,

Abstract / Introduction:

The most successful manufacturing companies develop a culture of full-accountability in their

operations where it matters the most, on the plant floor. It is the physical assembly line after-all where
the complex dance of human and machine takes place to turn individual parts into “products”. Gone are
the days of assembly line management and process control where software does not play a major role
in achieving this goal; it is now essential and the latest manufacturing execution system (MES)
technologies afford any manufacturer regardless of size the means to improve product quality while
optimizing cycle time.

Re-thinking the way you control your assembly line processes means evolving into the new
methodology of manufacturing operations management (MOM) and error-proofing that ties together all
branches of the complicated world that is the plant floor, into a command center that is a configurable
solution manufacturers can access from the cloud. By using software, the manufacturer is enabled
by knowledge; i.e. raw data that is transformed visually into meaningful reports manufacturers
use to improve their business.