1. THE ROLE OF MANUFACTURING EXECUTION SYSTEMS AND THEIR EFFECT ON QUALITY IN MANUFACTURING Christian Zrilanka ASQ Presentation Central North Carolina Section

2. Manufacturing Execution Systems (MES)  MES is a top-level manufacturing control system.  MES is comprised of computer servers and a Structured Query Language (SQL) database.  The MES communicates with Programmable Logic Controllers (PLC’s) and SCADA (Supervisory Control and Data Acquisition) systems.  The MES is a key component to an organization’s Enterprise Resource Planning (ERP) system.

3. MES Benefits  MES systems, by definition, bring an entire process under control.  Gives an organization “vision” into a process.  Provides an approved means of data collection by governing bodies.  Provides unlimited possibilities for quality control and/or monitoring.

4. Current Manufacturing Data Acquisition  Data can be manually obtained.  Data can be manually retrieved from PLC memory, analyzed, and counted.  Data can be manually retrieved from SCADA systems, analyzed, and counted.  Data can be manually retrieved after a manufacturing process has been completed by analyzing final product.

5. MES Manufacturing Data Acquisition  Data can still be manually obtained, as needed.  Data is automatically retrieved from PLC memory and saved in SQL database.  Data is automatically retrieved from SCADA systems and saved in SQL database.  Data is automatically retrieved after a manufacturing process has been completed by analyzing final product and storing findings in SQL database.

6. Quality Functions Within A MES System  Quality processes are divided into two categories within the MES:  Control of those systems that have built-in Statistical Process Control (SPC)  Actual control of those processes that are governed by Statistical Quality Control (SQC) processes

7. SPC Controlled Processes  Processes controlled by SPC systems will continue to be “locally” controlled by those systems.  SPC systems are monitored by MES systems with supervisory controls  Alarms, Key Performance Indicators (KPI’s), and other parameters are stored and monitored by MES.

8. SQC Controlled Processes  Processes controlled by SQC systems will fall under direct control of MES system.  SQC systems are monitored by MES supervisory controls.  Alarms, KPI’s and other parameters are stored and monitored by MES by separate MES “dashboard” programs.

9. MES and Quality  MES systems provides “data at your fingertips” for use in control charts and other quality functions.  Data can easily be imported into other programs—such as Microsoft Excel—for further representation and analysis of data.  MES systems provide real-time quality control data that keep processes in control.  MES stores data in approved manner by governing bodies.  Allows organization to “visualize” processes.  Allows organization to be proactive rather than reactive.  Reduces human intervention errors for more accurate quality control information.