Transcription
improvemanufacturing performancewith harmonized MES/MOMYour business technologists. Powering progress
Improve your manufacturingperformance with ManufacturingExecution Systems / ManufacturingOperations ManagementAtos’ Manufacturing Execution Systems or ManufacturingOperations Management (MES/MOM) power progress for today’sand tomorrow’s discrete and process manufacturers. Systemsthat used to be called MES have now evolved into encompassingsolutions for the shop floor: Manufacturing Operations Management(MOM) solutions.Atos understands the challenges faced bydiscrete and process manufacturers. We alsohave deep knowledge of manufacturingprocesses, and the technologies neededto optimize them.We can help you design, build and operateMES/MOM systems that provide tangiblepayback on your investment, and reducerisk to the business.The right solutions from Atos will reduceinventory, liberate cash, optimize resourceusage, and accelerate time-to-market. Wecan also help cut IT costs and overheads,by harmonizing and consolidating existingsolutions from across all company plantsand facilities.People talk about a general shift towards aservice-based economy – but the physicalreality of our world continues to beshaped through manufacturing.2Improve manufacturing performance with harmonized MES/MOM
What shapesour world?What is it that shapes the world in which we live? It is the productsand materials which result from manufacturing enterprises.Our lives are surrounded by objects andexperiences which did not exist in forms thatour grandparents could have recognized.It’s true for the products of discretemanufacturing: the interactive white-boards inour children’s classrooms; the mobile phonesthey use to text us; the hybrid cars we use tocollect them; the contactless credit cards forentry to the 3D cinema. And it’s not only about‘high-tech’ – just look at the objects aroundyour home or workplace.It’s true too for the output of processmanufacturing: for everything from medicinesto cleaning products, from fizzy drinks topaints, oil and gas.“ In both discrete and process manufacturing, the pressureis on to transform complex production and supply chaindata into tangible improvement and innovation. MES/MOMbecomes pivotal – but the need to reshape the manufacturingIT landscape can be a bit like clearing out the loft at home.You know it needs doing.You know that if you did it, you’d gain space and add value.But you don’t even want to open that little door in the ceilingbecause you know what’s behind it!”In the West, people talk about a general shifttowards a service-based economy – but thephysical reality of our world continues to beshaped through manufacturing – and on anincreasingly global scale.Improve manufacturing performance with harmonized MES/MOM3
Setting the paceof globalizationConsumerperspectiveWalk down the street orenter a store in Paris, Pasadenaor Phnom Penh to see howglobal brands dominate.ManufacturingperspectiveManufacturers have always driven globalization.Today, globalization is central to success in allareas of manufacturing industry. Pointers toglobal inter-dependencies are everywhere,from consumer and industry perspectives:Markets are global withopportunities and threats comingfrom every direction.At the same time, witness theexplosion in mass-customizationacross entire segments ofproduction (just think ‘build-toorder’ in automotive).Production networks areglobal with multiple owned/managed facilities oftenspanning continents.Supply chains are global withthird party provision anddistribution crossing almostall national boundaries.4Five business pressure pointsOn an increasingly open global stage, discreteand process manufacturers face distinct andunrelenting pressures:Quality, regulation and complianceAs a manufacturer, you bear the responsibilityfor the product and for the environment inwhich it is produced. Quality is the singlebiggest influence on brand and reputation, andit must be guarded jealously. Regulation andcompliance, though imposed from outside,underpin behavior and traceability, and mustbe managed consistently at every plant andfacility under your control.Cost control, cash flow and compressionIt is much easier to spend money than to earnit. You must optimize efficiency right across thesupply chain, driving out siloed thinking and theassociated expense of sub-optimal inventory.This is not simply about reducing operationalexpense – it is about adding to the bottomline and to your business agility. Compressingprocess to make it leaner and more efficientis key to competitive advantage.InnovationIf you don’t create the future, somebodyelse will. Innovation is not necessarily aboutend products: it’s about being smarter withvariable run-cycles, making orders of any sizeprofitable; about being able to synchronizeprototyping with daily batch production; aboutthe choreography of supply, and much morebesides. These are the factors which becomecritical in accelerating time-to-market.GrowthIf continuous growth is part of your strategy(and it usually is) – you have to keep growing,whether organically or through mergers andacquisitions. Whichever approach you employ,you have to continually optimize resource andasset use, and drive standardization across yourgrowing operational base.SustainabilityEnvironmental sustainability is front-of-mindin all areas of business and commerce.Manufacturers are under particular pressure toconvert reduced CO2 emissions into balancesheet benefit. In addition, waste, waste waterand energy efficiency are all improved as youmake first-time-right a reality. But sustainabilitygoes beyond environmental responsibility.It’s also about social sustainability – making surethat your product meets changing societal needs,and about the economic sustainability whichwill keep you in business long into the future.Improve manufacturing performance with harmonized MES/MOM
MES/MOM: promise andthe practiceMES/MOM can make a direct contribution tomeeting these business challenges. Intelligentlyconceived and implemented, the results can betransformational. Think of this transformation interms of three complementary focus areas:ManufacturingHow to ensure a common workable viewof data across distributed operational andproduction systems. There are two primarygoals here:uTou allow people and plant to increaseoperational efficiency and quality bysharing relevant data from previouslysiloed systems and processesuTou provide like-for-like performancedata for management acrossdepartments and sites, giving themthe dashboards and KPIs they needto tune and improve operations.Supply chainThe supply chain must be considered as part ofthe extended enterprise. The more effectivelythat actionable information moves across thesupply chain, the more opportunities you haveto reduce both lead-times and inventory. Thisis essential for improving agility in both thevolume and mix of product.Improve manufacturing performance with harmonized MES/MOMProduct innovationManufacturing collaboration is about morethan optimizing the operations and supplychain. Breaking down information silos alsohelps shrink time-to-market for new productdevelopment: successful product innovationmust get the right data to the relevantproduction processes on time. Similarly,improved integration between design chainand manufacturing processes aids productinnovation by delivering timely feedback onthe manufacturing viability of new products.MES/MOM first appeared in the early 1990s,conceived as a bridge between businesssystems and real-time production operations.Initial promise did not live up to expectations.Back then, three areas of concern stood out:1. Cultural readiness – manufacturingwas less agile 20 years ago, and in mostindustry sectors, awareness of thecapabilities and benefits of MES/MOMwas low.2. Business complexity – the bigger thebusiness, the tougher it is to change.In this context, although MES/MOM promisedmuch, these very real challenges impededadoption: it was too complex and too resourceheavy; mature MES/MOM products andspecialist resources were tough to find; and,as always, continuity of operations remainedthe business priority.Our methodologyis the result ofinvestment andexperience,encapsulatingindustry bestpractice forour clients.3. Technological complexity – even basicdata interchange between productionsystems was a challenge.5
The time is nowToday, Atos is positioned to help large manufacturing enterprisesaccelerate MES/MOM implementation. Times have changed, andforward-thinking manufacturers now understand that productionand process optimization, pro-active supply chain control andcontinuous innovation are all business imperatives and mustall be supported with advanced and dependable IT solutions.MES/MOM is now a viable bridge betweenprocess control and business managementsystems. Atos will design and build your MES/MOM solution to ensure that it delivers valueacross the three tiers of manufacturing, supplychain and design chain.Supply chain(Reliability, assets& responsiveness)Atos’ MES/MOM capabilities are underpinnedby its solid and actionable M4MESmethodology. M4MES has been developedby Atos specialists, and is the result ofinvestment and experience, encapsulatingindustry best practice for our clients.By definition, MES/MOM demands extensiveand meticulous interfaces with both processcontrol and business information systems.Depth of knowledge and experience in bothof these very different areas is critical, and wehave a demonstrable track record in both.SupportSourceMake(Cost, time,WIP, quality)DeliverDesignProduct lifecycle(Time to market, agility)As a highly-experienced system integrator,Atos works fluently with the world’s leadingMES/MOM application specialists, helpingensure that our clients make the rightchoices and gain the maximum benefit.6Improve manufacturing performance with harmonized MES/MOM
Atos will design and buildyour MES/MOM solutionto ensure that it deliversvalue across the three tiersof manufacturing, supplychain and design chain.Improve manufacturing performance with harmonized MES/MOM7
MES/MOM inaction with AtosAtos has successfully delivered more than 400 MES/MOM projectsfor large international manufacturing enterprises. Although benefitsare naturally specific to the individual business, the overall focus onimproved operations, on supply chain and innovation remains truefor all our clients.When you design and build military aircraft,managing as-designed, as-planned and as-builtbaselines is critical. MES/MOM is key in thedesign chain, providing product and processspecification to production, and processtraceability during and after production.For this leader in defense aviation, Atosapplied its M4MES methodology to optimizespecification and budgeting for the MES/MOMimplementation, handling interfaces betweenall related ERP and PLM systems.Atos helped a leading global truckmanufacturer radically improve process control,work instruction authoring, visualization andtraceability. Their new MES/MOM solutionsupports continuous process control anddelivers the insight needed for empiricalanalysis and continuous process innovation.A global leader in professional documentmanagement systems sought to replace itslegacy MES/MOM implementation to increaseproduction, improve quality and eliminatebottlenecks. The Atos MES/MOM solutiontracks and collects process and product data,enabling critical analysis and improving qualityand throughput.This top consumer dairy brand insists on itscustomers getting the same taste every time.Our customer needed to track and tracemillions of cheeses as they mature – and toimprove throughput. Our solution contributesdirectly to higher yields and gives managementeasy access to an aggregated real-time viewof production and business databases.Aerospaceand defenceLaboratory testing is a critical elementand significant cost in the production ofveterinary medicines. The Atos MES/MOMimplementation for this specialist laboratoryservices provider reduced cost, increasedthroughput, and most importantly, liberatedskilled scientists from clerical drudgery.This multi-national chemical company waspaying too much for maintenance acrossa distribution production network, and wasfinding it hard to identify and exploit bestpractice. The MES/MOM solution designedby Atos translated a Tower of Babel into oneindustrial language and allowed the client tonegotiate a single support contract for thefirst time in its history.AutomotiveManufacturing Operations ManagementPharmaceuticalChemicalsHigh tech8Consumerpackaged goodsImprove manufacturing performance with harmonized MES/MOM
How do we do it?While paying complete respect to all issuesof client confidentiality, we encourage theopen exchange of ideas and experience.This contributes to our growing repository ofre-usable business and IT project elements.Examples include user-requirement analysisand process best practice. The availability ofthese business and IT elements:Atos’ proposition as a partner for MES/MOMadoption hinges on two strengths:uActionableuM4MES methodologyuDepthuof experience and global reachin manufacturing processes and IT.M4MES MethodologyThere is nothing theoretical or academicabout the Atos M4MES methodology forMES/MOM adoption. It provides a solid,executable framework designed to helpcomplex manufacturing enterprises identifyneeds and opportunities. It allows you to pilotand experiment safely, and to schedule andimplement in a way which is both repeatableand geared to continuous improvement.Our M4MES methodology, is founded inbest practice and this has clear and practicalbenefits for adopters: every project weundertake contributes to our library ofbest practice.Unlike many IT solutions and servicescompanies, our expertise extends equally intoSCADA/machine control and into businessinformation systems. We are, for example, theleading exponent of control systems for nuclearpower production, on the one hand, and aregular winner of SAP innovation awards, onthe other. For MES/MOM, our specialities inERP and PLM are particularly relevant.uAcceleratesuand improves analysisuReducesuproject costsuIncreasesureliability and reduces risk.We recognize the value of the many MES/MOM application specialist companies activein the open market, and seek an impartial andvendor-independent position from which tooffer our clients professional guidance on thebest choice.Depth of experienceMES/MOM, perhaps more so than many otherindustry specific areas of IT, derives its valuefrom the ability to integrate data from multiplesources. For this reason, the extended industryknowledge of Atos becomes absolutely centralto our MES/MOM proposition.Overall, Atos establishes a proposition of‘design, build, operate’, and this also holds truefor MES/MOM, according to the needs andpractices of the individual client. The massivevolumes of real-time data generated by MES/MOM, for example, can be hosted, processedand managed in Atos secure, green datacenters, if desired.Finally, Atos’ position as a global player withcoordinated global resources makes a criticalcontribution. Today’s leading manufacturersoperate on the global stage, and it is essentialthat the partners they choose are able tosupport MES/MOM rollouts and support atany plant and in any location.Best practice industrial librariesConsumerpackaged goodsProcess libraryChemicalsDiscrete libraryAerospace & defenceAutomotiveHigh tech electronicsFramework repositoryModeling frameworkISA-95Manufacturing opportunity scanManufacturing maturityStakeholder challengesManufacturing opportunitiesBenefits assessment.Improve manufacturing performance with harmonized MES/MOMBPMManufacturing IT scanRequirements and architectureManufacturing IT solutionCost assessment.SCORRational unifiedprocessImplementation methodologyBPM and requirementsAnalysis and designBuildTestDeployment.9
10Improve manufacturing performance with harmonized MES/MOM
Clear businessand IT benefitsManufacturing enterprises must achieve standardization andconsistency across the extended enterprise. The ability to leveragedata from both business and production systems is critical to thisconsistency. Ideally, you need to cookie-cut best practice with easeacross plants and continents.By selecting Atos as a partner for MES/MOMadoption, manufacturing companies gain apracticable approach to data aggregationacross their own enterprises, and mostimportantly, from across the supply chain.This aggregation is the foundation ofprocess optimization. These engagementsare extremely focused: nobody wants(or is prepared to pay for) mega-projects.Because Atos brings the skills and its M4MESmethodology needed to layer MES/MOMacross existing production and businesssystems, our clients’ own IT teams are notover-stretched by these initiatives.Atos is experienced in both the technical andhuman implications of MES/MOM adoption.We will ensure that the change is welcomedfrom the shop floor to the board room, andthat business benefits are understood by all.Cost reduction targetsProcessesProduction KPIsQuality3% to 7% yield increase150K to 3M lessscrapped materials2% less process defectsRegulatoryperformance30% to 50% lessexception handling timeLead timeuAcceleratedudesign, execution andmanagement of MES/MOM projectswith minimized risk.15% to 50% less cycletime20% less changeoversWIP andinventory20% to 50% less WIPRevenue opportunity targetsCustomerservice5% more scheduleattainmentThe ability to make engagement easy is atthe core of our business ethos. We designpractical steps to adoption with measurablereturn at every stage. Because the extendedand consistent adoption of MES/MOM acrossthe manufacturing enterprise has such adirect impact on business performance, it isimportant that key business and IT decisionmakers understand its potential.Atos offers compact introductory sessionsto MES/MOM designed for non-IT specialists,and we are happy to arrange these at yourconvenience. Practical outcomes are important,and an MES/MOM Opportunity Scan willprovide a clear framework for your subsequentbusiness decisions.Success will depend on close partnershipbetween your IT experts and our own, andwe offer a series of MES/MOM engagementoptions for a more technical audience. Recently,our Manufacturing IT Scan and ManufacturingIT Roadmap sessions have been provinghot items.Whichever path you choose, we will followthrough with substantiated proposals, and lowrisk opportunities to experiment and explore.Over 50% of our manufacturing clients arealready actively engaged in MES/MOM.10% more on-timedeliveryNew productintroductionImprove manufacturing performance with harmonized MES/MOM58% less idle time8% to 18% productivityincreaseBecause of Atos’ experience in both businessand IT best practice, our manufacturingclients gain:uTheubusiness advantage of MES/MOM– optimized and consistent processesacross manufacturing operations andthe supply chain25% to 7% less signaturereview timesNext steps50% shorter NPI cycle11
About AtosAtos is an international information technologyservices company with annual 2011 pro formarevenue of EUR 8.5 billion and 74,000 employeesin 48 countries. Serving a global client base, itdelivers hi-tech transactional services, consultingand technology services, systems integrationand managed services. With its deep technologyexpertise and industry knowledge, it workswith clients across the following market sectors:Manufacturing, Retail, Services; Public, Health &Transports; Financial Services; Telecoms, Media &Technology; Energy & Utilities.Atos is focused on business technology thatpowers progress and helps organizations tocreate their firm of the future. It is the WorldwideInformation Technology Partner for the Olympicand Paralympic Games and is quoted on the ParisEurolist Market. Atos operates under the brandsAtos, Atos Consulting & Technology Services,Atos Worldline and Atos Worldgrid. For moreinformation, visit: atos.netFor more information, contact: dialogue@atos.netatos.netAtos, the Atos logo, Atos Consulting, Atos Worldline, Atos Sphere, Atos Cloud, Atos Healthcare (in the UK) and Atos Worldgrid are registered trademarks of Atos SA.April 2012 2012 Atos.
Atos' Manufacturing Execution Systems or Manufacturing Operations Management (MES/MOM) power progress for today's and tomorrow's discrete and process manufacturers. Systems that used to be called MES have now evolved into encompassing solutions for the shop floor: Manufacturing Operations Management (MOM) solutions.
