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MES

Synchronization, coordination, analysis and optimization of production processes

CURRENT STATUS OF MANUFACTURING EXECUTION SYSTEMS IN RUSSIA AND AROUND THE WORLD

MES stands for specialized software solutions designed to tackle the tasks of production scheduling and management. The purpose of such systems is to synchronize, coordinate, analyze and optimize production processes at a certain production facility. MES can be industrial complexes or software solutions deployed in workshops or at production sites.

A broad selection of management systems offered by both national and foreign vendors acts as a deterrent. The customer considers such a variety of systems and vendors and the lack of methodology that would help select a system for a particular application as a risk factor. Because of this, the customer may choose to wait before implementing the system even though the need to enhance production management efficiency is quite obvious.

EFFECT OF MES

Increased
performance:
90%
40%
Shortened production cycle:
60%
20%
Reduced energy consumption:
50%
15%
Reduced cost:
30%
10%
Production companies that are using MES
Production companies that are not using MES
Companies around the world see their performance indicators change over 3 years after adoption of MES

Introduction of MES without adjusting your business processes may do more harm than good

TOOLS UTILIZED FOR PROJECT IMPLEMENTATION

IMPLEMENTATION STAGES

  • 1

    SET UP A DEDICATED WORK TEAM

    It is necessary to set up a work team using your staff. The work team will be responsible for:

    learning about the system

    introducing the system to the other staff members / training

    dealing with the system vendor (Integrator)

    In the case of smaller companies, the work team can consist of one responsible person

  • 2

    HAVE YOUR RESPONSIBLE PERSON LEARN ABOUT THE SYSTEM FUNCTIONALITY

    Following the guidelines provided by the Integrator, the responsible person will install the system on the company computers and start exploring the possibilities of the system with the help of the manual.

  • 3

    MAKE SURE YOU INPUT INITIAL DATA

    One should make sure the information about the orders is input in a timely and consistent manner. New data should be input upon receipt of new orders. Every order should be broken down to separate production operations.

    The company leadership should appoint a person who will be generating new orders.

  • 4

    SUPPORT THE PRODUCTION PROCESS MODEL

    РBy regularly importing data on new orders in the system, the responsible staff member acts as a plant dispatcher:

    using the system, he/she draws up production schedules;

    as much as possible, he/she makes corrections to the schedule in real time guided by the updates from the field personnel or the foreman.

  • 5

    INPUT DATA BY MEANS OF REMOTE ACCESS

    The company will purchase the required number of cheap (possibly, used) PCs. The responsible person will set them up where they can be accessed by the field personnel and will create a local area network by integrating them with the computer running the main system module. After that, the dedicated person will install a remote access programme on the computers and show the personnel how to work with the system.

    After such training, the employees will be responsible to input information about the beginning and the end of each operation in a timely manner. It is a very simple action: one just needs to type in the password and push a button. However, we would recommend considering introducing a system of rewards for timely and careful data inputs.

  • 6

    ANALYZE SYSTEM UTILIZATION

    Once steps 1 to 5 have been implemented, one can consider that the basic implementation stage is completed. At this stage one will have a better idea about possible issues, as well as about the scope of customization that would be required. The Integrator will be able to use the terminology adopted by the company and the company will be able to formulate questions considering the key concepts and capabilities of the system.

  • 7

    DEEPER CUSTOMIZATION

    Should the company feel the need for a deeper system customization, we will jointly consider what items will need to be further customized. This is followed by preparation of a customization plan.

    Our experience shows that some of the arising issues can be resolved by better organizing and tuning up the system. In this case, the Integrator will provide all necessary information support.

    To resolve the other issues will require some customization. In this case, a separate agreement is signed.

    The timeframes and methods of further system customization will depend on the customer’s wish list and actual site capabilities.

PRINCIPAL FUNCTIONS OF MES AS DEFINED BY MESA

RESOURCE ALLOCATION AND STATUS

This functionality helps manage resources (such as machines, tools, operating procedures, materials, equipment) and other objects. It provides a detailed history of resources and ensures correct functioning of the production equipment and real-time monitoring of electrical equipment

OPERATIONS/DETAIL SCHEDULING

This functionality ensures detailed scheduling of operations based on priorities, attributes, characteristics and properties of a certain type of product. It also determines an optimum level of equipment utilization for a particular shift

DISPATCHING PRODUCTION UNITS

This functionality ensures online monitoring and dispatcher control over the production process. It monitors the production status, equipment and labour utilization, as well as execution of orders and batches. It also does a real-time monitoring of operations to ensure the execution of the production plan. All changes are monitored in real time and adequate adjustments to the plan are made

DOCUMENT CONTROL

This functionality makes sure the supporting documentation (manuals, standards, execution techniques, drawings, standard operational procedures, part programs, production run records, reports of engineering changes) has relevant contents, ensures information transfer from shift to shift and enables to keep logs of production plans and reports. Data archiving is also available

DATA COLLECTION/ACQUISITION

This functionality ensures interaction between various production subsystems for the purpose of receiving, collecting and transferring process and control data circulating through the production environment. Production status data can be input manually or they can be transferred automatically and at a set interval from process control systems or directly from production lines

LABOUR MANAGEMENT

This functionality delivers information about the personnel at defined intervals. This includes time sheets and attendance reports, monitoring for certification compliance, the possibility to monitor and manage the key and additional responsibilities of the personnel (e.g. preparation activities, expanded work area, etc.)

QUALITY MANAGEMENT

This functionality delivers the product quality control data (including real-time data) collected from the field level and thus ensures proper quality control while highlighting critical points. By analyzing correlation dependencies and the cause-and-effect relationships of the control events, it can offer adjustments for a particular point

PROCESS MANAGEMENT

This functionality monitors a specified production operation and can make automatic adjustments aimed at correcting or improving the operation or it can offer an appropriate solution to the operator

MAINTENANCE MANAGEMENT

This functionality ensures support of the maintenance operations with regard to the process equipment and tools during the entire production process

PRODUCT TRACKING AND GENEALOGY

This functionality provides information about where and how a certain product item was handled. Status information can include: reports on the personnel dealing with this type of products, product components, materials from the supplier, batches, serial numbers, current production environment, violations, individual product data sheets

PERFORMANCE ANALYSIS

This functionality provides reports on actual performance and compares the current performance indicators with the previous and expected ones. Such reports can include such measured parameters as resource utilization, resource availability, resource cycle time, compliance with the plan, standards and other parameters

MAJOR PROJECTS

KUMZ

Production process control system for aluminium sheets and plates at a new rolling mill plant

Uzbekugol

Centralized dispatcher control system for the Angrensk coal strip mine

Tulachermet-Steel

Production control systems for the steel section mills, which are a part of the casting and rolling complex

Asha Metallurgical Plant (AMZ)

Rolling Mill No.1

Magnitogorsk Iron & Steel Works (MMK)

An integration project for Sinter Plant No.5

Magnitogorsk Iron & Steel Works (MMK)

Cold Rolling Mill Complex: An integration project for the production process control system

EuroChem

An integration project for the Ground Phosphate Rock Line

NLMK

A product data management system for planning and scheduling

NLMK

An order preparation and route generation system for planning and scheduling

HISTORY OF MES DEPARTMENT

«Our first MES project began in 2011 when we signed a contract with Asha Metallurgical Plant. This customer trusted us, and we are still partners with them. The production monitoring and management system established by us is still in action and has been evolving together with the site,»

Aleksandra Kochneva, MES Department Manager at KONSOM GROUP

Soon after that project had begun, our department took up another project, of no less importance. The next project was implemented for Kamensk Uralsky Metallurgical Works and it was rather comprehensive. We were to build a MES system responsible for aluminium sheets and plates at the new rolling mill facility. We integrated several related areas in a single system read more

  • MES for hot and cold rolling mills;
  • complete integration with all the production lines in automatic mode;
  • network infrastructure management;
  • integration of utility and electric power supply systems

Organizing work is never an easy task. It is about a proper and efficient interaction between departments, as well as internal and customer relations. Our department encompasses both analysts and developers, who work like links of one chain, and each of them contributes to the final result. Analysts are the first who get involved, and only after they have done their part (they build business processes and get them approved with the customer; they make sure they know about all the needs of the customer, etc.), developers come into play.

A few different areas of system development are distinguished inside the department, that’s why a few teams have been created. Thus, one team specializes in applied components of MES (modules, applications, etc.). The second team is engaged in the development of a general concept for MES architecture, which enables us to use the same platform for different sites. The third team is working on developing planning and scheduling solutions.

Today, the Department boasts quite an extensive project portfolio, and each project is of value for us. The spectrum of our customers includes Asha Metallurgical Plant (Amet), KUMZ, Tulachermet-Steel, NLMK, Magnitogorsk Iron & Steel Works (MMK), Tutaev Motor Plant, EuroChem, Uzbekugol. Our solutions cover such areas as steel making, steel section mills, rolling mills, mining and mineral processing, planning and scheduling.

In 2015, Aleksandra Kochneva joined KONSOM GROUP hired as Manager of the MES Department. Thanks to the contracts that were signed between 2015 and 2020, the Department expanded to 30 personnel, among them there are developers, analysts and system architects. It means that KONSOM GROUP’s MES solutions are in demand and of relevance for the Customers.

MES Department

27 members:

  • 1 - manager
  • 4 - lead Specialists
  • 5 - lead Engineers
  • 10 - cat. 1 Engineers
  • 2 - cat. 2 Engineers
  • 5 - cat. 3 Engineers