1. Gold Keystone Sponsors
Digitizing the Supply Chain - New Product Development & Introduction (NPDI) MESA unConference May 5, 2014
Platinum Keystone Sponsors
Gold Keystone Sponsors
Welcome to MESA’s Unconference on …
Please be sure your registration information was captured at the door.
We promise not to spam you, but to keep the conversation going.
And note also that is one of the exits – others are XXX (if any)

2. Format for this Session
What is an Unconference?
MESA Content to start discussion
MESA Working Group hot topics
Discuss your questions and expertise
Create action items for MESA
Learn from each other
Experience what MESA Knows!
This is not primarily a presentation session, but a community discussion. We will be addressing issues everyone in this room shares, so Please be prepared to participate today.
And please also recognize that we use what our UK colleagues call the Chatham House Rule:
When a meeting is held under the Chatham House Rule, participants are free to use the information received, but neither the identity nor the affiliation of the speaker(s), nor that of any other participant, may be revealed.
So what that means is you can confidently ask questions and share your expertise without fear that you will be breaching company confidentiality. We are taking notes only for the purpose of being able to follow up with you, as that has often been requested.
We have some MESA content and hot topics that we believe will start the discussion.
Then the objective is to have a useful discussion where everyone shares openly.
Another objective is for you to help drive what MESA does next! So be thinking and get ready to participate.

3. Introductions Erik Nistad, Mondelez International
Director, Enterprise Business Services,
Integrated Supply Chain Standards & Solutions,
Vice Chairman, MESA Americas Board
Mike Williams, The Dow Chemical Co.
Recently Retired
MESA Americas Board Member at Large
photo
photo
I’m XXX
And with me to moderate and guide the session is XXX

4. Introduction to MESA International
MESA is…
…building bridges-of-understanding from the Plant to the Enterprise
…to drive clarity on the role and value of modern Information Technologies in production operations
MESA International is a non-profit industry association
We focus on IT in production operations – across all manufacturing and production segments.
And one area of long-time focus is plant-to-enterprise information flows.
We are the premier community for networking and peer-reviewed content on these topics.

5. Global Education Program
How MESA Delivers
MESA International: Building Bridges-of-Understanding from the Plant to the Enterprise
Peer -to- Peer
Points -of- View
Global Education Program
How does MESA operate?
Working from the bottom of this slide up,
MESA speaks with a voice stronger than any individual – with the entire range of practitioners
How we operate is with three main pillars:
Network of the most knowledgeable, experienced and passionate people about production IT spanning the globe
Rich peer-reviewed content in an array of white papers, implementation frameworks for plant-to-enterprise integration, research studies, guidebooks, and presentation materials by those with deep experience
Instructor-led accredited training to give your team a leg up wherever they are in the world and on their journey with production IT
All of these activities allow MESA members to have a stronger voice as well as greater success.
Today, we’ll discuss just one of dozens of MESA topics…
Speaking with the Voice of Industry’s Practitioners

6. MESA’s Working Groups Recipe Transformation Working Group
Founded in mid-2013
Focused on establishing a common “language” for transforming a formula or bill-of-material into an executable recipe.
Open for new members (must join MESA to participate)
Chaired by Erik Nistad, Director, Enterprise Business Services, Integrated Supply Chain, Mondelez International
Contact:

7. Why are we (you) here?
It takes too long to get products from R&D to a customer
We are still using stone age tools to move information from R&D to full production!
And we use the same tools multiple times for every technology transfer
In all process industries!
How do we get the right information transferred at each step in the process?
Fly engineers to the appropriate site
The equivalent of wandering minstrels or sitting around the campfire and exchanging stories
And not sure if the right info is getting across

8. There is a Better Way Common Language to define how to make a product
Common meaning and structure for the information
From Laboratory to Pilot Facility to Production Facility
Between production facilities for technology transfers
Across production stages

9. Your Ideal process The ideal process has:
Information created only once
Information is available to all parts of the company that need it
Information is guaranteed correct and up to date, and
Information is understandable by all parts of the company and suppliers

10. The Real Process Unfortunately in the real process:
Information is lost and must be rediscovered
Groups work on incomplete information
Groups work on out of date information
The information is inconsistently understood
Information is not shared with suppliers

11. Enterprise Recipe Management
Standard Process Descriptions for products for:
Technology Transfers
Site sourcing decisions
Investigations & Studies
MES and Batch Startup
Co-development
Sustainability
ERM is a STRATEGY not a tool
It is a method for faster technology transfers
It is a method to support faster investigations and better production data collection
It is a method to reduce the time and effort required to build production (Master) recipes
Captures site best practices for more consistent multi-site quality

12. ERM Information Information for automated technology transfers
Definition of equipment independent manufacturing processes
Information for QbD (Quality by Design) Design Spaces
Information for lean manufacturing studies
Information for multi-site investigations
Information for sustainable manufacturing
Information for contract manufacturing …

13. Why ERM Increased Regulatory Agency confidence with our processes
Same structure / format across all sites
Recipe development down to days instead of months
Consistent approach to recipe development across sites for product transfer
Faster / More RFT Development
Will achieve a higher level standardization of manufacturing process
Following industry standards & learning from others
Improving site to site knowledge of processes (sharing)
Supports basis for site to site supply chain evaluation (standardized processes)
Highlight
EBR development
Consistency in approach
Connections to other systems
Improving site to site knowledge

14. The ERM Concept ERM Standard Process Descriptions for Products
based on
Standard Definitions of Manufacturing Operations
using
Standard Quality Attribute Definitions (CQA, KQA)
and
Standard Process Parameter Definitions (CPP, KPP)
Standard Process Report Definitions
ERM
Definitions of manufacturing functions are product independent
Within manufacturing functions are defined CQA and CPP
Also determine wheat reports of data need to be generated

15. Automatic, Executable Recipe Generation
Has anyone tackled automatically converting info from NPDI to “executable recipes”?

16. Three Processes Creation of a core set of process actions
Creation of site specific, equipment constraints
Creation of General Recipes
This is how our working team see’s this process working and would like to discuss it with this group

17. Core Processes Implemented By A Team Of SME’s
Create a core library of Process Action definitions
Create a core library of Equipment Constraint definitions.
Create sample General Recipes for existing products to validate the libraries.
Maintain the libraries and distribute to the sites and R&D.

18. Processes Implemented By Site Process Experts (SPE)
Create and maintain a local library of Recipe Segments that implement the process actions on the site’s equipment.
Create and maintain the equipment maps that define the layout and material flows through the site’s equipment.
Create, using the transformation algorithms defined later in this paper, master recipes from the General or Site recipes provided by the core team or R&D.

19. Processes Implemented By R&D
Create General Recipes as the definition of how to manufacture a product, using the definitions in the Process Action and Equipment Constraint libraries
As new processes are developed, work with the SMEs and the SPEs to develop and define additional Process Actions and/or Equipment Constraints.

20. Output Are Libraries Used In ERM
A Process Action definition library
A library of Process Parameter definitions, used in Process Action definitions
A library of Quality Attribute definitions, used in the Process Action definitions
A library of Units of Measure, used in the process action and Equipment Constraint definitions
A library of Process Report definitions, used in the Process Action definitions
An Equipment Constraint definition library
Site recipe segment libraries
General recipe libraries

21. Automation
With these definitions and libraries it is then possible for software to automate the creation of master to control recipes for a specific site

22. Questions? What do all of you think?
Does this make sense to you / your organization?
Has anyone been able to cost justify an ERM type approach?

23. Barriers To NPDI Introduction And Operational Excellence
Acknowledgement:
Original slides extracted from 2003 MESA report by EDS
Reference to MESA white paper PLM Guidelines
Updated for MESA 2014
Mike K Williams
MESA member
The Dow Chemical Company – retired
represented 2014 MESA –Industry Week UnConference

24. Typical NPDI Environment
Design – Planning – Manufacture
ERP
Supply Chain
Product Scheduling
Develop & Scale
Product
Enterprise Recipe Mgmt
eBOM missing
Material Composition
Equipment Capability
Shop floor
Execution
Process Control
R&D
Manufacturing

25. Are these your current processes?
EBOM
Drawings
Models
Specs
ECO’s
Work instructions
ECO’s
Routings
MBOM
Execute
Plan
Shop Floor
Line 1
Line 2
Line 3
Line n
Design
The old concept of “throwing it over the wall” between design, planning, and manufacturing still applies to many companies today. When the systems of design, planning, and manufacturing are not connected through a digital backbone, one of two things generally happens:
Change management and process coordination works with few errors, but manually managing this process is extremely inefficient.
Change management and process coordination does not work, resulting in scrap, lost cycle time, and rework.
1st Transformation
2nd Transformation

26. Now imagine coordinating a Refinery

27. Configured work package
The integrated view
Production Orders
Process Configuration
Op. Routing
Work Instructions
Consumables
Characteristics Assignment
Shop-floor Reqs.
Tooling
Data Collection fields
Operator Certification
Configured work package
Shop
Floor
Execution
Process
Definition
Reconciliation and
Change Requests
Product Produced
Material Consumed
Machine Time utilized
ERP
E-BOM
M-BOM
Characteristics
Prod. Configuration
Product
Definition
The Waltz has three steps:
PLM
POM
OEE
Enterprise Recipe Management
- The glue

28. Benefits of Integrated POM-PLM-OEE
Creates an unambiguous communication from product and process definition to the point of manufacture
Configuration management applied to product and process derive work package for a specific work order
Direct, associative re-use of product definition data right to the shop
Feed back to design and supply chain planning:
on production performance
Process capability
Fast, accurate change implementation
Delivers the right data, right time and place
Avoids data re-entry error
Saves time and skilled labor
Expedites Product and process improvement
Provides improved CAPEX utilization

29. More Resources
MESA Whitepaper: June 2013 – “Using General Recipes for Standardized Multiple Plant Manufacturing Science”
MESA Whitepaper: November 2008 – “Manufacturing Science Model Extensions to Address Lean Manufacturing and Lean Supply Chain”
MESA Whitepaper: November 2008 – “An Iterative Refinement Approach towards a Structured Recipe Design”
MESA Whitepaper: March 2008 – “Manufacturing Science Model Extensions to Address Product and Process Sustainability”
MESA Whitepaper: April 2003 – “General to Master Recipe Transformation, Capturing Best Engineering Practices in Recipe Generation”
MESA Whitepaper: October 2002 – “From a Corporate Product Specification to a Control Recipe: It's not a Transatlantic Trip”
MESA Whitepaper: October 2002 – “General Recipe: Multiproduct Facility Design; Technology Transfer”
100s of materials available to Premium members
at no additional charge
Speaker: Please find and list appropriate MESA resources or ask the Working Group or Technical Committee leaders to assist you with that.

30. Why MESA? Join the conversation at: www.mesa.org
Global community for improving Operations Management with IT Best practices & guidance to drive productivity & profitability Global Education Program raising competency for production IT success Facilitate innovation for real-time Plant to Enterprise (P2E) integration Be heard and drive industry forward
Our association, MESA International, is 20 years old, and it is a worldwide community of people who are all passionate about production businesses. I have learned more and made more life-long industry buddies in MESA than I’d ever dreamed possible.
You need to get actively involved in MESA International.
Learn best practices from others with deep experience
Educate your team
Facilitate understanding
Make your voice heard to move the industry forward
Join the conversation at:

31. To Improve Your Success…
To access all of that and continue to be part of this conversation, please join us.
We offer memberships for companies and individuals, and you will meet the most experience people in IT for production operations from around the world if you join and become active.
Visit the MESA booth in the middle of the exhibit hall starting tonight and then for the next few days. Or talk to any of us or the folks at the table outside for more information.

32. Thanks for Participating!
Erik Nistad, Mondelez International
Director, Enterprise Business Services,
Integrated Supply Chain Standards & Solutions,
Vice Chairman, MESA Americas Board
Mike Williams, The Dow Chemical Co.
Recently Retired
MESA Americas Board Member at Large
MESA Enterprise Recipe Transformation Working Group
photo
photo
We really appreciate your active participation today.
If you enjoyed this conversation and learned something or feel you contributed, realize it is like many conversations that occur every week in our association.
We are passionate about the use of IT in manufacturing operations, and hope you will join us to move our industry forward effectively.

33. Thanks for Participating!
Moderator #2 Name
Job Title/MESA Title
Contact info
Moderator #3 Name
Logo (if applicable)
photo
photo
Logo (if applicable)
We really appreciate your active participation today.
If you enjoyed this conversation and learned something or feel you contributed, realize it is like many conversations that occur every week in our association.
We are passionate about the use of IT in manufacturing operations, and hope you will join us to move our industry forward effectively.