Times are challenging. The impact of the unexpected Covid-19 pandemic, the increasing dynamics of demand, supply chain issues and the “usual” operational challenges are having a significant impact in a manufacturer’s life.

It is not only what happens within the four walls of the factory. We can only deliver a perfect order if we collaborate closely with our partners in the end-to-end value chain and with product lifecycle partners. Perfect order delivery calls for visibility and transparency, and requires consistent and timely information.

Advanced technologies and concepts help us become less dependent on our resources and more agile. They also enhance workers’ skills and offer tools for further improvements.

In this introductory course, we learn that best-in-class means standardize and digitalize, and that a holistic approach in line with strategy is required. MES/MOM applications are the tools that help manufacturers improve their performance and become more competitive. Manufacturers must select the right MES/MOM solutions (from many) based on and matching their operational processes.

You will learn to:

• Discuss the current market drivers for global and smart manufacturing
• Recognize how market drivers are rapidly evolving and requiring real-time intelligence in manufacturing plants and across its supply chains
• Identify operational challenges
• Recognize the role of systems integration, collaboration and technology with respect to a successful use of MES/MOM solutions

Agenda

• Trends and Observations in Manufacturing
  • Impact of the Covid-19 Pandemic
  • Operational Challenges
• What is Next? What Can We Learn from Others?
• Conclusions and Wrap-up

Current industry discussions focus on the actual role of manufacturing/production in the global supply chain network. For any manufacturer to be competitive, actual manufacturing operations activities must be highly interactive in supply chain and enterprise processes to achieve effective collaboration and competition. This is the domain of collaborative and flexible manufacturing operations management (MOM) system architectures.

This course introduces and explains the most relevant international MOM standards in the context of the challenges identified in the previous course, “MES/MOM Methodologies: Introduction (CoA).” Standards are collections of best practices. In this and the other courses in the CoA program, we explain how to apply them in response to these challenges.

The MOM standards, developed over more than 20 years, also form a solid foundation for the application framework for Smart Manufacturing and Industry 4.0

You will learn to:

• Discuss the business role of primary MOM standards
• Describe the primary MOM standards applied for flexible manufacturing operations management (MOM) systems architectures
• Apply and explain the major models of the ISA-95 standard
• Discuss the key elements of the ISA-88 and ISA-62442 standards
• Recognize how B2MML supports integration between various solutions

Agenda

• Introduction
• MESA Models
• ISA-95: Enterprise - Control System Integration
• ISA-88: Batch Control
• ISA-62443: Security for IAC Systems
• B2MML, BatchML
• SCOR, OMAC, OAGIS
• Conclusions and Wrap-up

Reference Materials:

1. MESA White Paper #25: An Overview and Comparison of ISA-95 and OAGIS
2. MESA White Paper #26: Related Manufacturing Integration Standards, A Survey

This course introduces and explains the various types of MOM solutions and their roles in the manufacturing operations systems landscape. Connectivity and integration between all manufacturing, business applications and more is increasingly important when facing the current challenges. To achieve this requires an enterprise application framework or information architecture.

Architectures for Smart Manufacturing and Industry 4.0 receive special attention. We explain integration and communication standards, like OPC UA and MQTT. To leverage the benefits of Smart Manufacturing and Industry 4.0 requires standardization and precisely defined processes and products. When first time right, efficiency and effectiveness are the goals, the need is to define and maintain manufacturing master data carefully. This may seem obvious. But, too often, master data are forgotten or only partially taken into account at best.

It is important not only for new product development and introductions to define how a product looks and how to put it together. For a manufacturer, this is crucial for any product or process at any stage to be successful. An excellent starting point is to maintain standardized and well-structured processes for manufacturing master data, supported by the right tools.

You will learn to:

• Describe the roles of the various MOM solutions
• Explain the mapping of MOM solutions to the ISA-95 activity models
• Identify the differences between the presented integration approaches
• Describe the elements of Smart Manufacturing architecture
• Explain the importance of Manufacturing Master Data
• Describe the role of PLM and NPDI and recognize the benefits
• Explain the importance of Master Data Governance and ownership

 Agenda

• What are MOM Solutions?
  • MES, LIMS, CMMS, APS, WMS, etc.
  • Examples
• Solution Architecture
  • Integration Architecture
  • Solutions and ISA-95 Models
• Architecture for Smart Manufacturing
  • RAMI4.0, Edge, 3 Tier, etc.
• Manufacturing Master Data
• PLM and PDM
• Governance: Organization and Ownership
• Conclusions and Wrap-up

Smart Manufacturing is not just about technology. It is not something you buy off the shelf. Smart Manufacturing is primarily about empowering people in manufacturing. There are many things that make Smart Manufacturing attractive, like new business models, supply chain and partner collaboration, self-correcting manufacturing, real-time response and flexible (agile) production with standardized processes. In this course, we discuss its core concepts.

The Fourth Industrial Revolution is (being) built on a solid foundation of the Third. Therefore, a mature MES/MOM serves as the backbone for Smart. A structured assessment of the current manufacturing capabilities is the input for a plan to improve and leverage the new and advanced technologies and methodologies of Smart Manufacturing and Industry 4.0.

In this course, we discuss the Singapore Smart Industry Readiness Index and how this tool can help you find out how ready you are. Maturity models help to create a shared vision of process improvement within the organization and to set priorities based on objective measurements.

An ISA-95 based maturity capability assessment delivers the current maturity level and provides guidelines for structured step-by-step improvement via a plan. In the roadmap, each MOM project ROI identifies corrective actions to mitigate risks through required change to organization structure, process, personnel and technology. Significant cost reduction is a matter of effective work processes across plants and supply chain operations for normal and abnormal operating states. The real solution for effective work processes requires simultaneous changes in organization structure, operations processes and employee skill sets, all enabled by MOM technologies.

When raising your manufacturing capability maturity, it is important to measure the progress of your smart manufacturing and continuous improvement initiatives. It is critical for manufacturing practitioners and executives to understand the power of real-time decisions for manufacturing operations metrics before and after linking them to financial and business level metrics. Learners better understand the differences between the various types of metrics and how to construct a metrics framework.

You will learn to:

• Describe Smart Manufacturing and Industry 4.0
• Discuss the core concepts of Smart Manufacturing
• Describe standards for Smart Manufacturing like RAMI4.0
• Explain why MES/MOM is the backbone of Smart
• Describe the use of the Singapore Smart Manufacturing Readiness Index
• Discuss the need for a Manufacturing Transformation Strategy
• Describe the Lean and Six Sigma methods and how MES/MOM supports those methods to improve
• Discuss the structure of the Manufacturing Maturity Model
• Describe the elements of a maturity assessment
• Explain the different types of metrics from different business levels and how they influence one another for effective optimization of the business processes
• Describe the Vollman decomposition as a tool to create a metrics framework

Agenda

• Smart Manufacturing and Industry 4.0
• Core Concepts of Smart Manufacturing
• Standards for Smart Manufacturing
• MES/MOM as Smart Backbone
• How Ready Are You?
• Continuous Improvement
• Manufacturing Maturity Model
• Manufacturing Capability Assessment
• How to Measure Performance
• Conclusions and Wrap-up

Reference Materials:

1. MESA White Paper #38: Building a Manufacturing Transformation Strategy with ISA-95 Methods
2. MESA White Paper #52: Smart Manufacturing – The Landscape Explained
3. MESA White Paper #53: MESA MOM Capability Maturity Model Version 1.0
4. MESA White Paper #60: Smart Manufacturing and Cloud Computing
5. MESA Guidebook: MESA Metrics Guidebook – second edition

Based on discussions with industry leaders and domain experts, the course explains how to construct a compelling business plan with a defendable ROI business justification for MOM solutions. Explained are how to quantify the form of operations process, its inefficiencies, its solution alternatives/compromises, benefits and plant migration path. We will discuss explicit examples of successful justifications. The course arms learners with information needed to understand and address the competition (internal and external) for the scarce resources that exist for today’s manufacturers.

This course also presents the main elements of the methodology to successfully select a “sufficiently good” MOM solution that achieves your business and operational objectives.

This best practice methodology is published in MESA White Paper #11 and updated with experience from many MOM product selection initiatives. We explain the prerequisites for starting the selection process, which include various types of requirements and specifications, and communicating them to potential suppliers. The selected “sufficiently good” MOM solution must achieve the elements of your business case.

The last part of this course is about the deployment of MOM solutions. This is where it all comes together. Projects need a framework or methodology. Next to the traditional project management methodologies PRINCE2 and PMBOK, we will discuss other options. You need more than a new MOM product; you need skilled implementers, too. Key is combining the best of both worlds by collaborating with suppliers and/or system integrators. Introducing new manufacturing software requires users to adopt a new way of working. This is intentional if you want to improve your performance as a manufacturer. You need user acceptance to deliver the targeted benefits.

You will learn to:

• Describe the ROI benefits equations and risk mitigation strategies
• Describe the difference between the macro and detailed ROI approaches
• Understand the role of strategic intangible benefits
• Describe the main elements of the methodology to successfully select a suitable MES/MOM solution to achieve business and operations objectives
• Describe how to create a shortlist of potential solutions quickly
• Identify evidence that the candidates on the shortlist are good enough (or not) to achieve goals and rank them in sequence of suitability
• Explain how to effectively communicate requirements and critical issues to potential suppliers
• Describe a process for final evaluation and ranking
• Explain different project methodologies and frameworks
• Describe the skills needed for the roll-out
• Discuss the importance of user acceptance

Agenda

• Introduction
• Prepare: Justification and ROI Modeling
  • Examples
• MOM Selection Methodology
  • Create a Shortlist
  • Final Evaluation and Ranking
• MOM Solutions Deployment
• Project Methodologies
• Prepare for Deployment Projects
• Importance of User Acceptance
• Conclusions and Wrap-up

Reference Materials:

1. MESA Guidebook: Lean Manufacturing Strategic Initiative Guidebook: Second Edition
2. MESA White Paper #4: MES Software Evaluation / Selection
3. MESA White Paper #7: Justifying MES: A Business Case Methodology
4. MESA White Paper #11: MES Product Selection: Best Practices