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MES to improve quality and predictability in complex manufacturing operations
MES to improve quality and predictability in complex manufacturing operations

May 6, 2021

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Large manufacturers, with multiple plants, often find it easy to implement Manufacturing Execution Systems (MES) across their plants. A beverage manufacturer, for example, can create an MES template that is replicated across plants. The manufacturer can do this because the plant itself is template-based, regardless of whether it is in Kuala Lumpur or in Kiev. This is not the case with all manufacturers. MES implementation can be tricky when a manufacturer’s plants are not of one type. This situation occurs when a business uses specialized plants to manufacture different components that go into the final product being delivered to a client. In such instances, the plants are different — leading to complications in implementing MES.

A classic example of the complication is visible in the operations of a global vertical transport integrator that makes elevators, escalators, and travellators. Components for a custom travellator being installed at a European airport could be manufactured and shipped from a variety of specialized plants. These plants could be located anywhere, from India to Mexico to China.

The components from these diverse plants are used to assemble or manufacture the travelator at the point of use (at an airport, inside a mall, in a commercial complex, etc.). Implementing a robust MES covering production, maintenance, quality, traceability, process governance, inventory control, and automating the complete MES, across multiple plants, poses an extraordinary challenge. It calls for exemplary technological experience and expertise.

A unique challenge for MES

When the demand for bespoke products is growing and at the same time the lead time to deliver products to buyers are shrinking, it is time to roll out an MES implementation across all plants - each manufacturing differs in components and uses unique assembly mechanisms but driven by the same operational metrics.

The problem can be appreciated better with an example. Consider the construction of the tallest buildings in the world. Elevator components from different plants must be shipped and assembled in synchrony with the construction. The Just in Sequence (JIS) requirement of components at the construction site raises the complexity further. In addition, every building and facility wants to configure the products differently. Some want a mirror in the elevator cars, others want high-tech wrap-around LED screens, mood lighting, custom flooring, handrails, communication equipment, control panels, safety features, etc. The size of the problem in terms of costing, accounting, commissioning, manufacture, and delivery places an enormous strain on planners and systems.

These multifaceted challenges can be solved by:

  • Bringing visibility to sales orders inflow and integrating it with manufacturing work orders
  • Globalizing and optimizing KPIs across 22 plants by replicating best practices from its plants
  • Harmonization to achieve consistency in quality
  • Integrating the supply chain with the MES platform
  • Integrating plant and warehouse automation with MES
  • Unifying the architecture
  • Connecting frontline workers who manufacture the product at the point of use to their supply units
  • Simplifying and improving inventory management

Corrective Action Preventive Action (CAPA) implementation allowed plants to track quality data at every stage, identify non-conformance, take corrective action, and prevent recurrence through root cause investigation. This proved to be a significant contributing factor in quality improvement.

At the bottom of this was the support and maintenance of the solution using best practices and certified MES product experts.

The value unlocked by MES

Planning and MES were tightly integrated, clearly focusing on managing inventory.  Any change in planning can now be quickly and accurately rolled into the MES. With this, the customer can unlock value through:

  • A 3% reduction in inventory carrying costs
  • A 15%reduction in component and product defects
  • Improved traceability and safety
  • Plant level, line level, and station level visibility
  • The ability to confirm delivery dates to buyers
  • Process governance, people management, and real-time performance monitoring
  • Reduced downtime with predictive and scheduled maintenance

Customers need a solution that offers cost-saving. MES integration provides significant cost savings to keep the existing systems in sync with orders and delivery commitments.

 

Author:

Shantanu Choudhary is a Global Practice Head for the Manufacturing Service Line of ITC Infotech. In his role, he works with customers in implementing digital solutions on the factory shop floor with a specialization in MES – MOM, IoT, and Factory Automation platforms. He has 14+ years of experience with having worked in the manufacturing sector for over 5 years in the core manufacturing operation and supply chain roles. He has successfully delivered and led projects for various domains in Packaging, Automotive, Industrial Equipment, Defense Equipment (MLRS – Multiple Launch Rocket Systems) & Artillery Shells, CPG, and High-Tech. He has been instrumental in setting up and creating an MES & IOT practice from scratch at ITC Infotech.

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Shantanu Choudhary
​​​​Global Practice Head, MES & IoT 

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ITC Infotech is a leading global technology services and solutions provider, led by Business and Technology Consulting. ITC Infotech provides business-friendly solutions to help clients succeed and be future-ready, by seamlessly bringing together digital expertise, strong industry specific alliances and the unique ability to leverage deep domain expertise from ITC Group businesses. The company provides technology solutions and services to enterprises across industries such as Banking & Financial Services, Healthcare, Manufacturing, Consumer Goods, Travel and Hospitality, through a combination of traditional and newer business models, as a long-term sustainable partner. ITC Infotech is a wholly owned subsidiary of ITC Ltd. ITC is one of India’s leading private sector companies and a diversified conglomerate with businesses spanning Consumer Goods, Hotels, Paperboards and Packaging, Agri Business and Information Technology. For more information, please visit: http://www.itcinfotech.com/

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