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Manufacturing Execution System

Manufacturing Execution System. Jun Alzona. Agenda. Terminology EDM / PLM PDM – Planning Data Management Process Plan Authoring Process Work Instruction Delivery-Shop Floor Control Data Packages Across Major Processes. Agenda. Requirement Definition Discussions Process Plans

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Manufacturing Execution System

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  1. Manufacturing Execution System Jun Alzona

  2. Agenda • Terminology • EDM / PLM • PDM – Planning Data Management Process • Plan Authoring Process • Work Instruction Delivery-Shop Floor Control • Data Packages Across Major Processes

  3. Agenda • Requirement Definition Discussions • Process Plans • Process Plan Revision • Plan Revision to Work Order Supersede • Shop Floor Control - Work Order Execution • Work Order Alterations • Work Order Alteration Propagation • After Market- Maintenance, Repair and Overhaul

  4. Terminology

  5. AVL Approve Vendor List • AM Asset Management • BO/Stamp Buyoffs • CHAR or IP Key Characteristics or Inspection Points of Engineering Design/ Drawing that are Common or Part Specific • D/C Data Collection • DP Data Package • EBOM Engineering BOM • ECO Engineering Change Order Terminology

  6. ECR Engineering Change Request • ECM Engineering Change Management • EDM Engineering Data Management • Effectivity - End Item or Component Date or Unit Effectivity that Drives Manu facturing Planning of Any Part - Can Dictate Routing, BOM, IP’s and Tools etc… to Manufacture or Assemble a Part • MBOM Manufacturing BOM (Work Order BOM) • MCO Manufacturing Change Order Terminology

  7. MRO Maintenance, Repair and Overhaul • PBOM Production BOM– BOM Used by MRP • PLC Product Life Cycle • PLM Product Life Cycle Management • PO/POLI Purchase Order /PO Line Item • PPP Process Planning Package (Data Package - Work Instruction) Contains Versions and Revisions of any Process Plans Related to a Particular Engineering Drawing Release Terminology

  8. PP Process Plan (Work Instruction) Contains All Revisions Associated to Process Plan as well as Detail Instructions and Required D/C etc…. • SFC Shop Floor Control • SM Supplier Management • WO Work Order Terminology

  9. Configuration / Product Structure • EBOM Engineering BOM • PBOM • Production BOM • The BOM Used by MRP/ERPs • May or May NOT Match Engineering EBOM but Still Per Engineering • Producibility is One of the Primary Reasons Terminology

  10. Configuration / Product Structure • MBOM • Manufacturing BOM or As Planned BOM (Work Order BOM) • A Snapshot of the PBOM • Can Have a Life of Its Own Terminology

  11. Configuration / Product Structure • ABBOM • As Built BOM (Work Order Material Transactions – Actual Component Usage/Issues) • Includes Remove and Replace Components –BUT is STILLthe AS BUILT • Reference BOM for MRO Type Orders Terminology

  12. Configuration / Product Structure • AMBOM • As Maintained BOM (MRO) • Remove and Replace Components of ABBOM = AS Maintained BOM • Becomes the Reference BOM for down the road MRO type activity Terminology

  13. Engineering Data Management

  14. NO Resubmit / Close Yes WIP Disposition Engineering Data Management: Product Life Cycle

  15. Planning Data Management

  16. Item Char Controls: Revision Date and or Unit Effectivity Optional Data Load or Interface Item Controls: Revision Serial Lot Heat Code Date Code Configuration Control Planning Data Package P or M BOM Controls: Revision Date and or Unit Effectivity Work Plan Controls: Version Revision Date and or Unit Effectivity Planning Data Management Process

  17. Plan Authoring Process

  18. E-Item E- BOM • Operation/Step Instruction with Operationalized • Work Instruction (Texts) • Components (PBOM) • Characteristics or IPs • Tools • Skills Requirements • Buyoff’s (Manufacturing, Quality & Customer) • Standard Text • Doc’s • Media • CAD Date or Unit Effectivity • Summary Tabs • Components • Characteristics or IPs • Tools • Skills Requirements • Buyoff’s (Manufacturing, Quality & Customer) • Standard Text • Doc’s • Media • CAD Plan Approval • Basic Operational Business Rules: • An Operation can have multiple Steps • Operation Steps are sequential by default • Operation Steps can also contain elements authored in an operation • You can have sequential operations leading to parallel operations and vice versa • Sequential and Parallel Operation rules enforced during execution • Completion at Operation Level ONLY, validation ONLY enforce if Step has any D/C Approved Plan UPDATE Yes NO = No Action Plan Authoring Process

  19. Work Instruction Plan DeliveryShop Floor Execution Process

  20. AS BUILT AS PLANNED D A T A P A C K A G E • Operation/Step Instruction with Operationalized • Work Instruction (Texts) • Components (MBOM) • Characteristics or IPs • Tools • Skills Requirements • Buyoff’s (Manufacturing, Quality & Customer) • Standard Text • Doc’s • Media • CAD • Summary Tabs • Components • Characteristics or IPs • Tools • Skills Requirements • Buyoff’s (Manufacturing, Quality & Customer) • Non Conformance • Corrective Action • Standard Text • Doc’s • Media • CAD Operation Complete WO Complete Routing Update Traceable Part’s Consumed Latest Plan Revision Plan Supercede Work Instruction Plan Delivery Execution Process

  21. After Market Maintenance, Repair and Overhaul

  22. Operation/Step Instruction with Operationalized • Work Instruction (Texts) • Common Components • Characteristics or IPs • Tools • Skills Requirements • Buyoff’s (Manufacturing, Quality & Customer) • Standard Text • Doc’s • Media • CAD Date or Unit Effectivity • Summary Tabs • Components • Characteristics or IPs • Tools • Skills Requirements • Buyoff’s (Manufacturing, Quality & Customer) • Standard Text • Doc’s • Media • CAD Plan Approval Routing Update After Market: MRO Planning Process

  23. After Market Maintenance, Repair and OverhaulExecution Process

  24. AS MAINTAINED D A T A P A C K A G E AS BUILT • Operation/Step Instruction with Operationalized • Work Instruction (Texts) • Common Components • Characteristics or IPs • Tools • Skills Requirements • Buyoff’s (Manufacturing, Quality & Customer) • Standard Text • Doc’s • Media • CAD • Summary Tabs • Components • Characteristics or IPs • Tools • Skills Requirements • Buyoff’s (Manufacturing, Quality & Customer) • Standard Text • Doc’s • Media • CAD Operation Complete WO Complete Routing Update Traceable Part’s Consumed After Market: MRO Execution Process

  25. Data Packages

  26. Manufacturing and Quality Processes E-Item E- BOM Yes Plan Supercede ConfigurationControl Entire Data package Production After Market Data Package Across Major Processes

  27. Ease of Use

  28. Ease of Use • Process Plan • Copy Plan • Copy Operation/s • Used of Standard Operation • New Plan Revision – electronic push to Shop Order/s with previous revisions • Alerts on Objects with Latest Revision • Characteristics • Media • Standard Operation etc…..

  29. Ease of Use • Shop Orders • Traceability (contains all related records such as NCs, Cas, P/Ns, Tools, Buyoffs, Alteration, media etc…..) • Alerts on Plans with New Revision • Ability to pull in Plan with Latest Revision • Proactive check at Operation and Work Order Level • Shop Order Alteration (Redlines) • Propagate to Other Work Orders • Push change upward to Process Plan • Alerts on Object with Latest Revision • Characteristics • Media • Standard Operation

  30. Ease of Use • Data packages • Online and Real Time • Reduce and or eliminate the need for Tribal Knowledge • Single Database • Audit and History • Access can be made available to customer

  31. General Requirement Discussion

  32. OEM (Original Equipment Manufacturing) • Process Planning Package • Process Plan • Operations • Operation Steps • Data Collections • Approval Process • Alerts General Requirement Discussion

  33. OEM (Original Equipment Manufacturing) • Shop Floor Control • Order Types • Operation • Operation Steps • Data Collections • Alerts • Holds • Non Conformance • Alteration • Approval Process General Requirement Discussion

  34. After Market • Master Planning Package • Master Plans • Plan Types • Work Scope • Subjects (Service Bulletins) • Operation • Operation Steps • Data Collections • Approval Process • Alerts General Requirement Discussion

  35. After Market (continued) • Shop Floor Control • Order Types • Operation • Operation Steps • Data Collections • Alerts • Alteration • Approval Process General Requirement Discussion

  36. Process Plan • Types • Version • Revision • Effectivity OEM: Process Planning Package

  37. Operation • Revision Control • Operationalized Components • Operationalized Characteristics • Manufacturing Type • Engineering Type • Revision Control • Operationalized Tools/Machines OEM: Process Planning Package

  38. Operation (continued) • Buyoffs • Manufacturing • Quality Inspector • Source Inspector • Engineering • Customer • Skill Requirement OEM: Process Planning Package

  39. Operation (continued) • Standard Operations • Standard Text • Multi Media (Image, Drawings, 3D Models etc…..) • Revision Control • Manufacturing BOM (Work Order BOM) – As Planned BOM OEM: Process Planning Package

  40. Operation Steps • The SAME Operation Authoring Capability • Sequential by Nature OEM: Process Planning Package

  41. Approval Process (QUEUES) • ME – Manufacturing Engineering • QA – Quality Assurance • Customer OEM: Process Planning Package

  42. Process Plan Revisions • ALERTS when a Plan is Viewed • Operation • Operationalized Components • Operationalized Characteristics – Part Number and Characteristics Combination Latest Revision Exists • Manufacturing Type • Engineering Type OEM: Process Planning Package

  43. Process Plan Revisions • Operation (continued) • Operationalized Tools – Obsolescence • Standard Operations – latest Revision exist • Standard Text - latest Revision exist • Multi Media (Image, Drawings, 3D Models etc…) - Latest Revision Exists • Revision Control OEM: Process Planning Package

  44. Revision Approval Process (QUEUES) • ME – Manufacturing Engineering • QA – Quality Assurance • Customer OEM: Process Planning Package

  45. Plan Revision and Supersede • Plan Requires a Revision to Accept Any Latest Revision Components or Objects • List of Work Order with Prior Revisions to Be Available when Viewing a Plan of the Latest Revision OEM: Process Planning Package

  46. Plan Revision and Supersede • User Can Select Specific Work Order for Plan Supersede • Plan Supersede Business Rules: • ONLY Pending Operation can be superseded • Active or Completed CANNOTbe superseded • Active Operation can be Superseded ONLY if the Following Conditions Exist: • No Component Parts D/C • No Characteristic D/C Exist • No Tools D/C • No Buyoffs OEM: Process Planning Package

  47. Work Order • Order Types • Version /Revision • Effectivity (Date, Serial and or Unit) • Serialized • Multi Serial • Each Serial Number Can Have and Will Have a Life of Each Own Within a Work Order OEM: Shop Floor Control

  48. Work Order (continued) • Lot Control • Lot and Serials • Each Serial Number Can Have and Will Have a Life of Each Own Within a Work Order • No Lot or Serial Control OEM: Shop Floor Control

  49. Work Order Status • Pending • In Queue • Active • Complete • Cancelled • Alteration Hold OEM: Shop Floor Control

  50. Operation Status • Pending • In Queue • Active • Complete • Active • Skipped • Alteration Hold OEM: Shop Floor Control

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