MES Excellence Centres Delivery Strategy for Manufacturing Execution Systems A modular working program designed from experience and best practices The result is a process where facts rather than opinions dominate the decision making process and whereby a truly Integrated Project Team delivers Excellence in both behavior and results. International B.V. 2008 The information in this document is the property of International B.V. and may not be copied, or communicated to a third party, or used, for any purpose other than that for which it is supplied without the express written consent of International B.V.
Delivery Strategy for Manufacturing Execution Systems MES Excellence Centres A modular working program designed from experience and best practices MES Work Packages Page 4 Page 5 Page 6 Page 7 MES Product Selection Page 8 MES Implementation & Integration Page 9 24/7 Page 10 Page 11 The result is a process where facts rather than opinions dominate the decision making process and whereby a truly Integrated Project Team delivers Excellence in both behavior and results. Aerospace & Defense Automotive Metals & Mining Energy & Utilities Electronics Food & Beverage Consumer Products Industrial Life Sciences Forest Products Oil & Gas Rubber Semi Conductors Chemicals Transportation & Logistics Page 2 International B.V. 2008 The information in this document is the property of International B.V. and may not be copied, or communicated to a third party, or used, for any purpose other than that for which it is supplied without the express written consent of International B.V.
Delivery Strategy for Manufacturing Execution Systems is an Independent Solution Provider, with over 20 years experience in the manufacturing systems arena and a wealth of experience undertaking Continuous Improvement initiatives and Manufacturing IT solution design, deployments and 24/7 support assignments. Many world-class multinational manufacturing companies engage in their improvement initiatives, Manufacturing IT deployments and the 24/7 availability of their manufacturing operations. customer references include: Toyota Motor Manufacturing, Rolls-Royce Aerospace, Carlsberg Breweries is the world leading Manufacturing Execution Systems specialist with global delivery capabilities. The key of our success is our professional s passionate approach and ability to facilitate change by keeping a laser sharp focus on improvements in our customers manufacturing environment. The excellence teams around the globe have the ability to transform complex manufacturing subjects into a standard generic approach. The result is a process where facts rather than opinions dominate the decision making process and whereby a truly Integrated Project Team delivers Excellence in both behavior and results. Belgium United Kingdom Industry Expertise Controls Expertise Program Management Expertise MES Expertise Germany IT Expertise International HQ The Netherlands Lean & Six Sigma Expertise Spain Czech Republic United States Canada Australia Austria With 10 MES Excellence Centres in the world stretching from Melbourne Australia to Detroit USA, streamlines global manufacturing operations. delivers a full project life cycle from consulting, implementation, and training to 24/7 support. Our Strategic Partnership Package offers a win-win situation with a truly collaborative approach and long-term commitment for both our customers and. The Strategic Partnership includes On- Site Support Agreements, World-wide Training Certification, Service Level Agreements and Software Maintenance Agreements. Business Case MES Selection & Specification MES Implementation & Integration Page 3 International B.V. 2008 The information in this document is the property of International B.V. and may not be copied, or communicated to a third party, or used, for any purpose other than that for which it is supplied without the express written consent of International B.V.
Delivery Strategy for Manufacturing Execution Systems Software Development MES Work Packages Implementing a Manufacturing Execution System is often a large IT project involving and affecting many resources in the manufacturer s organization. The key goal is to deliver maximum benefits and generate an optimal Return on Investment meeting the requirements and needs of the organization. has been acting as a mediator, consulting and integration partner for many world class manufacturing organizations globally to assess, select, deploy and support manufacturers in their MES program. has deployed many MES systems in various industries over the last decades including Automotive, Aerospace & Defense, Metals & Mining, Energy & Utilities, Electronics, Industrial, Food & Beverage, Life Sciences, Forest Products, Oil & Gas, Rubber, Semiconductors, Chemicals, Transportation & Logistics and Consumer Products industries. has developed a generic approach in delivering Manufacturing Execution System solutions to our customers. This standard approach incorporates lessons learnt and best practices gained from and other implementations. It provides a guideline in implementing an MES solution and can be tailored to our customer needs. The work packages have a modular based approach which allows our customers to fit the services to their requirements and needs in each stage of the MES program. What you will find in this document is an overall program of work being divided into seven modular work packages, each with it s own work program. Products Training Consulting Projects On-Site Support The MES key success factors: The work packages are delivered through Consulting, Projects and On-Site Support 1. Creating Awareness with a strong supporting role for Training, 2. Personnel Engagement Software Development and Products. 3. Full commitment of your staff 4. Transparency 5. Fact based approach and decision making process 6. Laser sharp focus on your business improvements Page 4 International B.V. 2008 The information in this document is the property of International B.V. and may not be copied, or communicated to a third party, or used, for any purpose other than that for which it is supplied without the express written consent of International B.V.
Page 5 Delivery Strategy for Manufacturing Execution Systems 1. The is especially designed to provide additional education and awareness for the executive teams, project teams and stake holders in the MES program. The content of the workshop will be tailored to the specific needs and requirements of your organization taking the knowledge level of the teams into account. Presentations (theory and examples) as well as practical exercises bring the introductions to life. workshops are interactive, the workshop chairman will always make sure the workshop contents link back to your situation. Duration: 1-3 days: depending on the knowledge levels, team focus and interest grouping. The covers: Building understanding of MES by explaining MES according to the MESA model and ISA-95 standards. Introduction on the (strategic) market developments and overview of the main products available in today s MES market. s experience with these products are shared and discussed. How to align all stake holders in your operations when realizing an MES deployment. Introduction of MES benefits and best practice realization examples. How to build a successful MES roadmap incorporating your Continuous Improvement Initiatives. Modular MES Working Program And answers high level questions? Why does the IT Team think MES can be done at the ERP Level? Why does the Production Team think MES can be done at the Controls Level? What is the truth? A short introduction to Manufacturing Execution Systems, standardization processes (S88 & S95) and the real world of MES. Who is using MES today? Who is successful? Who is failing? and Why? Which MES products should you include in your selection process? Does MES interfere with your current Continuous Improvement initiatives? What are the benefits and pitfalls? International B.V. 2008 The information in this document is the property of International B.V. and may not be copied, or communicated to a third party, or used, for any purpose other than that for which it is supplied without the express written consent of International B.V.
Page 6 The Discovery Assessment covers: Clarification of Objectives - Assistance with the determination of the key business and technical goals, for which a solution is required. Establishing direction and vision Existing State Analysis Map existing infrastructure and systems and understand the task ahead. Modular MES Working Program Delivery Strategy for Manufacturing Execution Systems 2. MES Discovery Assessment MES provides benefits, but how could your organization benefit from MES? What to implement and where does it make sense to implement? The standard assessment matrix mapping leverages the experience of our customers. It offers the opportunity to have a structured and cost effective MES scan providing a basis for a solid business case and concept design. In addition the Discovery Assessment provides guidance in defining the business and technical goals that the solution requires. And answers some common questions? What are the business goals? What are the technical goals? Who are the stake holders? What functionality do we need? How do we build a successful MES project organization and incorporate that into our daily business? Is our organization ready to implement MES? International B.V. 2008 The information in this document is the property of International B.V. and may not be copied, or communicated to a third party, or used, for any purpose other than that for which it is supplied without the express written consent of International B.V.
Page 7 Prerequisites are: A general understanding of MES and the existing state of infrastructure and manufacturing equipment. Duration: 7-12 days depending on complexity, information available and number of manufacturing facilities. The covers: Evaluation of vision Evaluation of business goals Evaluation of technical goals Interviews with corporate management, line management and individual departments, like Engineering, Quality, Production, Maintenance and IT Detailed sessions on cost calculations with Finance Benefits scan shop floor and top floor assessment Modular MES Working Program Delivery Strategy for Manufacturing Execution Systems 3. The driver is business improvement and not a new IT system. IT should be a key enabler to drive those improvements, but how to create transparency in cost versus benefits? has assisted many manufacturing organizations in creating business cases. The business case development requires a truly collaborative approach where consultants closely work with the customer s team in defining a solid business case. Leverage our experience with MES implementations, understanding the benefits and costs! Smurfit Kappa EON, Australian Water Arcelor, Corus, SMS Demag Centocor, Johnson & Johnson Ford, Toyota, Visteon Procter & Gamble, Duracell Carlsberg, Friesland Foods, Heineken And answers business questions? How much does an MES project cost? Where are the improvements? What do the improvements deliver financially? How can we pay for MES? Which MES functionality brings the most benefits? What is the right sequence of implementation? Best fit funding structure? International B.V. 2008 The information in this document is the property of International B.V. and may not be copied, or communicated to a third party, or used, for any purpose other than that for which it is supplied without the express written consent of International B.V.
Modular MES Working Program Delivery Strategy for Manufacturing Execution Systems 4. MES Product Selection Taking the emotion out of the product selection is often asked to act as a truly independent consulting party to assist manufacturers with their MES selection process. Nowadays there are over 200 commercially off the shelf available MES software packages. keeps a detailed track of about 50 leading MES packages available in the market. Based on the statement of requirements can quickly bring transparency and help in selecting a short list of products suitable for your organization. will act as an extension of your organization providing knowledge and experience. The result is a process where facts rather than opinions dominate the decision making process. An additional service is available, assistance with procurement to lower long term cost of ownership. The MES Product Selection covers: Gap analysis on existing infrastructure and future infrastructure? As is to to be. Statement of Requirements MES Product scan and creating shortlist Assistance in Request for Information and Request for Proposal process Assistance with conference room pilots Assistance with reference site visits Assistance with Procurement process Takes the emotion of the Product choice process Concept design And answers burning questions? Which potential products can be considered for our organization? What are the criteria needed when selecting an MES product? Which templates from can we use to reduce the time required with Requests for Information (RFI s) and Requests for Proposal (RFP s) How to weight the responses to RFP s and include the answers in the contractual responsibilities of the product supplier? How to assess pricing and the opportunities for reducing prices? How to assess the RFP s, conference room pilots, reference site visits? How to approach final negotiations and final product choice? Page 8 International B.V. 2008 The information in this document is the property of International B.V. and may not be copied, or communicated to a third party, or used, for any purpose other than that for which it is supplied without the express written consent of International B.V.
Page 9 Face up to and eliminate the top 8 most common causes of project failure: Recognize the potential for failure Act now and during all project stages on all 8 points Focus upon: Strong Project Management (Prince2 Methodology) Involvement (Marketing Campaign 2 way communication) Risk Management Project Success Potential Roadmap Learning together (involvement) Benefits realization Change Management: Business Benefits Management Change Program Management Process Design Organization Design Culture and Behavior People Development Modular MES Working Program Delivery Strategy for Manufacturing Execution Systems 5. MES Implementation & Integration s strong project management methodologies, gated process and collaborative approach deliver MES projects on time and within budget. provides a full project life cycle implementation and integration of the MES solution and its components. Going beyond implementation and integration supports a change in culture and adoption of modern work practices. Empowering your organization and maximizing benefits of the MES solution. Implementation: Blueprint Design Functional Design Specification Use Case/Technical Design Specification Software configuration/development Installation Commissioning Testing Factory Acceptance Test (FAT) Site Acceptance Test (SAT) Documentation; hardware & software, networking and other system components Delivery of user training and coaching Project Management International B.V. 2008 The information in this document is the property of International B.V. and may not be copied, or communicated to a third party, or used, for any purpose other than that for which it is supplied without the express written consent of International B.V.
Modular MES Working Program Delivery Strategy for Manufacturing Execution Systems 6. Manufacturing Execution Systems are production critical systems and require effective support. Ensuring 99,9% availability requires effective and robust support models with clear communication structures. offers a mix of services tailored to meet the exact requirements of the customer. provides both local (physical) and remote support with rapid response times supported by a Global Helpdesk, often integrated with our customers IT or IT Outsourcing partner and the users. We know the demands of the manufacturing world and what it means to react NOW! Service Level Agreements (SLA) An SLA provides the client direct access to systems experts with a clearly defined response time. Depending on the level of support agreed between and the client, a systems expert can be on-site within hours after taking the call. An SLA can be agreed as a Global agreement covering multiple sites with plant-specific agreements. Local, single location or area specific SLA s are all possible within s flexible agreement structure. Software Maintenance Agreements (SMA) Software Maintenance Agreements provide enterprises with essential software upgrades, updates, repair of bugs, telephone support and user groups at a fixed rate. An agreement will be made between and the client, which can be part of the software license agreement signed when the software is originally purchased or added at a later date. On-Site Support (OSS) The world of strategic shop floor partnering is well understood by. We share responsibility and become an integral part of your team. can take full responsibility for all your shop floor Automation and IT systems and act as the single point of contact for all your suppliers of factory equipment ensuring full visibility and compliance to standardization processes covering hardware and software, integration, infrastructure, and networking. World-Wide Training Certification (WWT) World-Wide Training Certification has value to both companies and employees who embrace the concept of lifetime learning and understand the value of knowledge and competence. It is intended for maintenance, engineering, IT, manufacturing and management personnel, combining a number of up-to-date training courses. By following this program, participants undertake a complete education program and acquire broad knowledge of business and automation aspects: lean/six sigma, design, programming and practical maintenance skills - bringing extra value to your team. Page 10 International B.V. 2008 The information in this document is the property of International B.V. and may not be copied, or communicated to a third party, or used, for any purpose other than that for which it is supplied without the express written consent of International B.V.
Modular MES Working Program Delivery Strategy for Manufacturing Execution Systems 7. Benefits Realization Consulting Unlocking all of the benefits of your Manufacturing Execution System is a service offered by. Maximizing benefits requires understanding and involvement of the shop-floor teams, planning, management and operators etc. It is an extension of the change management process already started during the MES process to ensure that data derived from the system will accelerate production performance by embedding new working practices and facilitating the change and realize process that sticks. Integrating MES implementations with business initiatives such as Lean/Six Sigma and Product Life Management turns MES into a true business solution delivering real business benefits. Use the MES system to lock down your Kaizen process! Page 11 International B.V. 2008 The information in this document is the property of International B.V. and may not be copied, or communicated to a third party, or used, for any purpose other than that for which it is supplied without the express written consent of International B.V.