MES/MOM METHODOLOGIES CoC

Times are challenging. The impact of the unexpected Covid-19 pandemic, the increasing dynamics of demand 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 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

Test and Exercises:

No test

Course Prerequisites:
None

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.” Standards are collections of best practices. In this course and others, we explain how to apply them in response to these challenges.

The MOM standards, developed over more than 20 years, 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, KPIML
• SCOR, OMAC, MIMOSA, OAGIS
• Conclusions and Wrap-up

Test and Exercises:

1. In-course Formative Assessment Test: 10 Questions, open notes in discussion, answers recorded in test form
2. Out-course Summative Assessment Test: 10 Questions, open notes in self-study, answers recorded in test form

Course Prerequisites:

None

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.

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 architectures
• Identify the use of OPC and MQTT

Agenda

• Introduction
• 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.
  • Communication and Integration
• Conclusions and Wrap-up

Test and Exercises:

1. In-course Formative Assessment Test: 10 Questions, open notes in discussion, answers recorded in test form
2. Out-course Summative Assessment Test: 10 Questions, open notes in self-study, answers recorded in test form

Course Prerequisites:

None

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 many of the 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.

You will learn to:

• Describe Smart Manufacturing and Industry 4.0
• Discuss the core concepts of Smart Manufacturing
• Describe the standards for Smart Manufacturing like RAMI, OPC and MQTT
• Explain why MES/MOM is the backbone of Smart
• Describe the use and structure of the Singapore Smart Manufacturing Readiness Index

Agenda

• Introduction: What is Smart?
• Smart Manufacturing and Industry 4.0
• Core Concepts of Smart Manufacturing
• Cyber Physical Systems, IoT & IIoT, Digital Twin and Digital Thread, Smart Factory and Smart Ecosystem, Machine Learning, Artificial Intelligence
• Standards for Smart Manufacturing
• MES/MOM as Smart Backbone
• How Ready Are You?
• Conclusions and Wrap-up

Test and Exercises:

1. In-course Formative Assessment Test: 8 Questions, open notes in discussion, answers recorded in test form
2. Out-course Summative Assessment Test: 8 Questions, open notes in self-study, answers recorded in test form

Course Prerequisites:

None

Reference Materials:

1. MESA White Paper #52: Smart Manufacturing – The Landscape Explained
2. MESA White Paper #60: Smart Manufacturing and Cloud Computing

Many manufacturers fail when they attempt Continuous Improvement (CI) initiatives without an aligned MOM system strategy. Many manufacturers fail when they attempt MOM systems without an aligned CI initiative. As a result, a new global Industrial Revolution has begun based on optimizing manufacturing plants by combining CI methods with an adaptive MOM system architecture put into place using a Manufacturing Transformation Strategy.

Though manufacturers are still transforming raw materials into valuable products, their needs have evolved.

Maturity models help to create a shared vision of process improvement within the organization and to set priorities based on objective measurements.

This course explains how to use ISA-95 to assess the current state and as a tool to design a future, improved way of working. A 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. Traditionally, industrial companies view manufacturing cost reduction as only a labor cost issue. Often, it is not even the biggest cost factor. 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.

You will learn to:

• Discuss the need for a Manufacturing Transformation Strategy
• Describe the Lean and Six Sigma methods and how MES/MOM supports those methods to improve
• Describe the structure of the Manufacturing Maturity Model
• Identify tools, such as ISA-95, that can help to assess current manufacturing (capability) maturity as a basis for a manufacturing systems roadmap
• Describe the elements of a maturity assessment

Agenda

• Introduction
• Why a Transformation Strategy?
• Supply Chain Management
• Continuous Improvement
• Manufacturing Maturity Model
• Four Domains: Process, Structure, People and IT
• Manufacturing Capability Maturity Assessment
• Conclusions and Wrap-up

Test and Exercises:

1. In-course Formative Assessment Test: 8 Questions, open notes in discussion, answers recorded in test form
2. Out-course Summative Assessment Test: 8 Questions, open notes in self-study, answers recorded in test form

Course Prerequisites:

None

Reference Materials:

1. MESA White Paper #38: Building a Manufacturing Transformation Strategy with ISA-95 Methods
2. MESA White Paper #53: MESA MOM Capability Maturity Model Version 1.0

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, it 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:

• Explain the importance of manufacturing master data
• Describe the role of Manufacturing Master Data Management
• Describe the role of PLM, PDM and NPDI and recognize the benefits
• Explain the importance of Master Data Governance and ownership

Agenda

• Introduction
• Definitions, Trends and Observations
• Product Lifecycle and New Product Development and Introductions
• Governance: Organization and Ownership
• Master Data Maturity
• Conclusion and Wrap-up

Test and Exercises:

1. In-course Formative Assessment Test: 8 Questions, open notes in discussion, answers recorded in test form
2. Out-course Summative Assessment Test: 8 Questions, open notes in self-study, answers recorded in test form

Course Prerequisites:

None

This course addresses the critical need of 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.

Approaching the link between operations and financial can be from both ends. The Vollman decomposition is applied to construct metrics models from an operations perspective. Examples introduced are the Three-layered Model and the Metrics Construction process, published in the MESA Metrics Guidebook (2nd edition).

Cost Accounting approaches such as Grenz Plan Kostenrechnung (GPK), Activity-based Costing (ABC) and Resource Consumption Accounting (RCA) start from the financial perspective.

While metrics approaches are reactive, analytics focus on continuous improvement. Application of Machine Learning, a subset of Artificial Intelligence, can help manufacturers improve decision-making in complex situations.

You will learn to:

• Recognize the increased decision-making capabilities of mapping operations metrics to financial and business metrics
• 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
• Recognize cost accounting approaches
• Describe the differences between metrics and analytics
• Identify the basic elements of data analytics and Machine Learning

Agenda

• Introduction
• Metrics Do Matter
• The Great Divide: Operations and Finance
• Metrics Models
• Cost Accounting Approaches
• Analytics
• Machine Learning
• Conclusions and Wrap-up

Test and Exercises:

1. In-course Formative Assessment Test: 10 Questions, open notes in discussion, answers recorded in test form
2. Out-course Summative Assessment Test: 10 Questions, open notes in self-study, answers recorded in test form

Course Prerequisites:

None

Reference Materials:

MESA Guidebook: MESA Metrics Guidebook

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. Exchange ideas, ask questions and get answers. Understand how other companies attack the issue of justifying plant and corporate investments in MOM projects and learn what tools and processes help.

Explained are how to quantify the form of operations process, its inefficiencies, its solution alternatives/compromises, benefits and plant migration path. Also discussed are risk management and mitigation strategies, solution competition (internal and external), impact to decision makers, business drivers and the overall capital approval process.

The session concludes with explicit examples of successful justifications. The course arms learners with information needed to understand and address the competition (internal and external) for scarce resources that exist for today’s manufacturers.

The end user, vendor and integrator need to work together to build the flexible Smart Manufacturing plant that will enable the developing “pull” economy. Together, we need to justify the MOM solution to business leaders as the technology needed for fast market response and even market creation, and to quantify the inefficiencies, risks, rewards, migration path, alternative/compromises, competition (internal/external), decision makers, business drivers and approval process. Once done, it gets simple.

You will learn to:

• Discuss key business elements used to justify MES/MOM projects
• Identify the solution competition (internal and external), impact to decision makers and business drivers
• Identify the overall capital approval process and the basic financials for the IT business justification
• 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

Agenda

• Introduction
• Justification Components
• Basic Financials
• ROI Modeling
  • Macro ROI Approach
  • Detailed ROI Approach
• Examples
• Conclusions and Wrap-up

Test and Exercises:

1. In-course Formative Assessment Test: 10 Questions, open notes in discussion, answers recorded in test form
2. Out-course Summative Assessment Test: 10 Questions, open notes in self-study, answers recorded in test form

Course Prerequisites:

None

Reference Materials:

MESA Guidebook: Lean Manufacturing Strategic Initiative Guidebook (2^nd Edition)

This four-hour interactive course 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, published in MESA Whitepaper #11 and updated with experience from many MOM product selection initiatives, comprises two phases:

1. Creating a short list of potential solutions quickly
2. Proving that the candidates on the shortlist are good enough (or not) to achieve your goals and ranking them in sequence of suitability

We explain the prerequisites for starting the selection process, which include determining 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. Therefore, the requirements will reflect those elements prioritized by potential added value.

We then elaborate the final evaluation and ranking, based on all gathered information. Using practical exercises, the learners obtain hands-on experience for the most important activities in the selection process.

You will learn to:

• Explain 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 short list 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
• Identify the prerequisites for starting the selection process
• Identify the types of requirements and specifications
• Explain how to effectively communicate requirements and important issues to potential suppliers
• Describe process for final evaluation and ranking

Agenda

• Introduction and Overview
• Organization and Kick-off
• Requirements and Specifications
• Creating a Shortlist
• Requirements Document
• Meeting Solution Providers
• Final Evaluation and Ranking
• What is Next?

Test and Exercises:

1. In-course Formative Assessment Test: 10 Questions, open notes in discussion, answers recorded in test form
2. Out-course Summative Assessment Test: 10 Questions, open notes in self-study, answers recorded in test form

Course Prerequisites:

None

Reference Materials:

1. MESA White Paper #4: MES Software Evaluation/Selection
2. MESA White Paper #7: Justifying MES: A Business Case Methodology
3. MESA White Paper #11: MES Product Selection: Best Practices

The last course within this MES/MOM Methodologies program is 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, there are other options like Waterfall, Agile/Iterative, Scrum, Kanban, Critical Path Method, Critical Chain Project Management and LEAN. In this context, GAMP 5 provides valuable input as well. 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.

Multi-site roll-outs have additional challenges, but offer opportunities with respect to template development, standardization, deployment scenarios and solution lifecycle.

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:

• Explain different project methodologies and frameworks
• Describe the differences between a single site and multi-site roll-out
• Explain the skills needed for the roll-out
• Discuss the importance of user acceptance

Agenda

• Introduction
• Project Methodologies
• Multi-site Roll-out
• Preparing for Deployment Projects
• Required Skills for Success
• The Importance of User Acceptance
• Conclusions and Wrap-up

Test and Exercises:

1. In-course Formative Assessment Test: 8 Questions, open notes in discussion, answers recorded in test form
2. Out-course Summative Assessment Test: 8 Questions, open notes in self-study, answers recorded in test form

Course Prerequisites:

None