Wonderware Operations Software

Improving Manufacturing Operations

Terence Tan
General Manager
MES

Definition according to MESA International:

Manufacturing Execution Systems (MES) deliver

information that enables the optimization of
production activities from order launch to finished
goods.

Definition according to ISA:

The MES layer focus in a group of activities

(operations, inventory, quality and maintenance
activities) corresponding to Level 3 in the
Functional Hierarchy model.
ISA Model
Level 4
Business Planning & Logistics
Plant Production Scheduling,
Operational Management, etc

Level 3
Manufacturing
Operations & Control
Dispatching Production, Detailed Production
Scheduling, Reliability Assurance, ...

Levels
2,1,0 Batch Continuous Discrete
Control Control Control
Purdue CIM Model

Level 4: Enterprise Resource Planning System

Level 3: Manufacturing Execution System

Level 2: Process Supervisory System(s)

Level 1: Real time Controllers

Level 0: Instruments and Actuators

The MESA model

Sales & Enterprise

Service
Management MES Resource
Planning

Operations/ Resource
Detailed Allocation &
Scheduling Status

Dispatching Document
Production Control
Units

Product
Performance
Tracking &
Analysis
Genealogy

Labor Maintenance Process

Management Management Management

Data
Quality
Collection
Management
Acquisition
Supply Chain
Control
Management
What is Wonderware MES?

Wonderware MES

Wonderware MES is an out-of-the box, configurable,

modular Manufacturing Execution System (MES)
software focused on production execution, shop floor
data collection and analysis.
Product History

March 2009 Wonderware Operations and Performance 3.5

February 2008 Wonderware Operations and Performance 3.4

October 2007 EPM 2.0 = Factelligence 3.1 + QuickStart

July 2007 Wonderware Factelligence 3.1

2002 First version of Factelligence by CIMNET

Wonderware MES Features

Electronic Work Order Management

Deliver planned vs. actual production using Recording of Production Events

Centralized Manufacturing Model

Improve process and production Production Rules
using
consistency Certifications

Real time inventory management

Detailed definition of materials, substitutes and
Improve inventory velocity using byproducts
Bill of Materials

Dynamic prioritization and sequencing

Reduce order lead time using Labor management
Connection to HMI/SCADA

Downtime
Monitor and analyze production Utilization
using
performance OEE
Licensing
Wonderware MES

Utilization and Downtime

OEE
Performance

Work Order Execution

Bill of Materials Production Events Tracking

Parameters Download
Operations
Operations Standard
Premium Data Collection

Inventory Certifications

Labor Management
Steps
Wonderware MES Architecture

Clients
Manager Custom
Configurator Supervisor Operator
.NET App
IIS

Middleware
Wonderware
Factory
MES COM+ Package
Connector
Service

Database Server

Production DB
Wonderware MES Middleware
Wonderware MES Client
System Requirement - Software
System Requirements -
Hardware
 Operations Software
Functional Overview
Quick Changeovers Between Products and Lines
Electronic work orders, BOM, specs
Work Order Execution
Delivering Planned vs. Actual Production
Specifications Work orders, data collection, symbols

Operations Bill of Materials Process and Production Consistency

Standard Templates, BOM, specs, security

Parameters Download
Improve Inventory Turns and Reduce Inventory Cost
Accurate recordkeeping, visibility
Data Collection
Reduce Order Lead Time
Inventory Dynamic allocation of production assets
Enforcement of production rules / steps

Operations Certifications Reduced Time-to-volume for New Products

Premium Map entity model, product / process context
Labor Management
Improved Compliance & Governance
Steps Electronic system records, history

Operations Software Standard Edition

Improve Productivity via faster product or line
Changeovers
Central administration of process and
product parameters
Maintain Bills of Material (w/ version mgt)
Product & material specs w/ min/max limits
per BOM entity
General recipe definitions using site
specific processes

Accurate equipment setup

Site specific product specifications
Automatic download of set points

User-based parameter management

Operator visibility of set point values (.NET
Controls)
Associate drawing, multimedia file or
documents to specifications
Build Operator dashboards tailored to
specific operation (InTouch, .NET controls)
 Faster Changeovers One
Version of the Truth
Electronic Bills of Material &
Specifications

Centralized administration
with version control
Faster Changeovers Accurate
Equipment Setup
Site Specific Product Specs

Auto Download of Set Points

 Faster Changeovers
Better Operator Visibility
Powerful Set of .NET Controls
for Building Operator Displays

Flexible Display Options

InTouch
Operator
Third Party HMI
Web
Respond Faster to Production Issues via
Planned vs. Actual Production Values
Electronic management of Work Orders
Ability to change job prioritization &
sequencing via Operator displays & job
summary .NET Control

Recording of production events

Material consumptions
Complete as built records per work order

Immediate detection of deviations

Specification or plan deviations
Real-time database captures full production
data record
Active alarm management system
Equipment & material
 Planned vs. Actual Production
Online Work Order Management
.NET Controls used in Operator
Displays

Visibility to Planned Values

Summary of Planned vs Actual

Production
Reduce Production Errors & Increase Yield
Consistent interpretation of
operating guidelines and procedures
Accurate paperless execution of work
orders & jobs
Show work instructions, SOPs,
drawings, NC programs

Central, detailed definition of user

privileges and security roles
Assign user rights per entity or process
Job based login
Common security definition using
ArchestrA security, including Operating
System integration

Central definition of process and

product parameters
Electronic Bills of Material
Define processes, specifications,
Classes
Execution of Work Orders
Create a Process

Create a Work Order

from the Process

Start and Monitor the

Status of a Work Order
Central Definition of Process &
Product Parameters
Electronic Bills of Material

Specifications

Processes
 Operations Premium Edition -
Functional Overview

Work Order Execution

Specifications

Operations Bill of Materials

Standard
Parameters Download
Improve Inventory Turns and Reduce Inventory Cost
Accurate recordkeeping, visibility
Data Collection
Reduce Order Lead Time
Inventory Dynamic allocation of production assets
Enforcement of production rules / steps
Operations Certifications
Reduced Time-to-volume for New Products
Premium Map entity model, product / process context
Labor Management
Improved Compliance & Governance
Steps Electronic system records, history
Improve Inventory Turns & Reduce Inventory Costs
via Accurate Records and Increased Visibility
Accurate records of actual material
consumptions and production levels
Automatic data collection
Broad inventory mgt functionality;
receiving, shipping, scrap, hold, transfers,
splitting/combining, re-classifying lots

Detailed definitions of materials

Bills of Materials
Material substitutes
Status information on raw materials,
Work in Progress (WIP) & finished goods

Immediate access to real-time

inventory status
Reduce Production Lead Time through Dynamic
Allocation of Production Assets

Electronic production order management

Ability to perform prioritization & sequencing
Enforcement of production rules

Flexible operational planning based on

accurate, detailed information
Actual production resource information

Dynamic allocation of production assets

Based on actual availability of material,
equipment or personnel
Reduced Time to Volume for New Products
via Enforcement of Production Rules
Rapid binding of process
capabilities and product definitions
Integration of ArchestrA plant model
with Operations production model
Detailed definition of sequencing of
operating activities
Manual/auto tasks
Steps (procedures)
Accurate records for cycle times,
yields, consumptions during initial
production runs
Common system environment for
model definition, execution and
operations
Ability to define Process State as
experimental or production
Ability to Certify resources according
to defined process State
Improved Compliance & Governance
via Complete Production Records

Complete electronic system

records for production, quality and
processes
Rapidly respond to unforeseen
events, such as product recall or
audits (internal, external)

Internal process harmonization

Share best practices and scale across
multiple installations

Help ensure safe operations with

enforcement of SOPs
Comply with environmental, health
and safety standards
 Genealogy & Traceability Reporting
Operations Softwares complete
data record & easy retrieval
make responding to
governmental information
requests straightforward & easy
Summary
Comprehensive MES Functionality
Bill of Material, Work Orders, Events, Data Collection,
Specifications, Set Point Download, Inventory, Certifications,
Steps/Procedures, Labor Management, User Management,
Genealogy, Traceability, Web Reporting
Fully Scalable
Functionality Standard & Premium Edition, Supply Chain
Connector, MES Clients
Physical Scalability equipment, lines, plants
Highly Integrated
Wonderware Connectivity
Historian, System Platform MX, OPC, Suite Link
Wonderwares System Platform
Single Industrial Application Development Environment
Wonderware InTouch
Worlds leading HMI
Software Solutions for Real-Time Success SM