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Introduction
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Product
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MES
2011
A Buyers Guide
Category
Introduction
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b u y e r s g u i d e se c t i o n s
Category Introduction
AMR
Research
first used the
term manufacturing
execution
system in
1992 as part
of its threelayer MES
model.
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he transformation of
the traditional factory from a production facility into a modern service
center has resulted in management
problems for which many manufacturers are not yet prepared. The
economic efficiency of modern value creation
is not a property of the products but rather
of the process that creates them. What this
means is that the decisive potential of companies is found less in production capability and
more in process capability.1
The requirement for process capability gives
rise to the requirement that all value-adding
processes be geared to the process result and
thus to the customer. A necessary condition
of process transparency is the ability to map
the companys value stream in real time,
without the acquisition process involving
major outlaya capability beyond enterprise
resource planning (ERP) technology, but
perfectly suited to manufacturing execution
systems (MES). 2
Manufacturing execution systems software is an increasingly critical component of
modern manufacturing environments. MES
collects and analyzes production data, tracks
quality control, and is frequently integrated
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b u y e r s g u i d e se c t i o n s
Category Introduction
as ingredient expiration date monitoring and
emergency shutdown systems.8
For manufacturers
to thrive in
the decades
ahead, they
will have to
deploy MES
across their
enterprise.
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Performance analysis
Quality management
Information management12
While the implementation of an MES
system is always challenging, the rewards
and return on investment are higher than
they have ever been.
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By providing operator support, production scheduling, tracking and tracing capabilities, and accurate, real-time visibility
into production processes, MES may deliver
the following benefits to a manufacturer:
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Process standardization
helps manufacturers
pool plant
capacities
across the
extended
enterprise.
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The global
economic
collapse has
forced some
manufacturers to
postpone or
limit plans
Many of the controls vendors increasingly
to upgrade or standardize their products around OPC specireplace their fications, making integration more cost effecexisting MES. tive and allowing IT to more easily abstract
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A new MES
can cost from
$150,000 to
$300,000 for
the software
license, plus
one-and-ahalf to three
times that
amount for
services.
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purchasing mindset is that SaaS vendors typically have limited transparency into breakdown of pricing (i.e., splitting out software,
hosting, and support).
3. Freemium remains common, but approaches vary widely. Many SaaS vendors
continue to offer various types of free trials
or free low-end editions to allow potential
customers to try the product before buying,
and to capitalize on the word-of-mouth that is
quite common among SaaS users. 24
Typical project payback for MES investments
comes in six to 24 months. Most MES projects
are justified on cost-reduction measures: lower
work in progress (WIP) and finished goods inventory (FGI); reduced waste, scrap, and materials;
reduced cost of regulatory compliance; reduced
rework; lower maintenance costs; reduced indirect labor costs; shorter cycle times; shorter lead
times; improved quality; and reduced process
and product variability.
Process improvements also accrue to the
ROI for MES investments: faster new product
introduction (NPI) cycle, shorter time to innovation, improved adherence to customer audit
requirements (traceability and genealogy),
and promotion of flow manufacturing.
Finally, overarching market improvements
are supported by MES: better collaboration,
improved supply chain visibility, and a platform for continuous improvement.25
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ompanies
should analyze the capabilities of
state-of-the-art MES to estimate what
an MES deployment should cost. what
would be a reasonable price?
Historically, MES setups were big bang implementations, where functionality needed to
be delivered immediately. These created large
projects and long time lines that frequently
failed to deliver an adequate business return
and often were not aligned to the current
business problems upon project completion.
SAPs introduction of xApp Manufacturing
Integration and Intelligence (SAP xMII), which it
bills as the worlds first manufacturing intelligence portal, is another example of technology advances offering better support for MES
deployment. Like ERP systems, MES solutions
have historically had two basic pricing models:
user-based and usage- or module-based. The
former entails one license fee per user, which
includes access to all modules of the system. The
latter means functionality is purchased on an a
la carte basis, plus an additional per-user fee.21
According to Simon Jacobson, a research director at AMR, a new MES can cost anywhere
from $150,000 to $300,000 for the software
license, plus one-and-a-half to three times
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Any supplier
not able to
integrate a
staff worktime function
and a performance-based
remuneration function
can be
ruled out.
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t is a daunting task
to identify criteria for selecting an
MES solution and, by extension, an
MES vendor. The more you understand
about the matter, the harder it becomes to keep an overview perspective.
Where should you start, and where
should you stop?
Once youve looked at multiple system
presentations, it may be difficult to see where
they differ; after a while, all user interfaces
can look the same.
MES setups are complex IT installations
that, depending on the form they take, can
affect a large number of functional areas in a
manufacturing concern. Systems may be used
for anything from straightforward feedback
regarding quality assurance and personnel
management to complex detailed schedulingcontrol systems.
Once objectives have been defined, a better assessment can be made of the scope of
services offered by different systems and suppliers. For example, if you want to start with
machine data collection but know that in a
year or two the company will be looking at incentive wages, you can immediately establish
knockout criteria. Any potential supplier not
able to integrate a staff work-time function
and a performance-based remuneration function can be ruled out immediately.
Consider the possible objectives that can be
met by the introduction of MES. This usually
means that quantifiable approaches can be
found, which then form the basis for calculating an ROI. Such a procedure is more efficient
and involves less work; further, the level to
which objectives have been achieved can be
better assessed for the purpose of controlling subsequent investments. The following
checklist should provide some assistance in
designing and selecting MES solutions: 26
General Criteria
1. Does the MES have fully integrated
production, personnel, and quality
management?
2. Does it support paperless production?
3. Does it include all necessary standard
products?
4. Does the system offer escalation
management and workflow functions?
5. What references and knowledge of the
industry does the supplier have?
6. How easy is it to adapt the MES
setups functionalities to the
customers processes?
7. Does the MES manufacturer have a clear
standard product and release strategy?
System Concept
1. Is the complete MES functionality
provided in a single system?
2. Can the individual components be
used as modules?
3. Can the functions be configured?
4. Does the MES have an enterprise
services architecture-oriented (ESA)
structure?
5. Does the system orient itself by
common industry standard products?
6. Does the system support the necessary
platforms?
7. Does it support the necessary
interfaces?
8. How easily can it adapt interfaces to
the requirements of the customer?
9. What possibilities does the system
offer for the customers own
developments?
10. Can these adaptations be made just
as easily at a later time?
11. What tools are available for preparing
ones own analyses?
12. Can the existing analyses in various
levels of data aggregation be adjusted
for all corporate levels?
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Production
1. Are there integrated functions that
offer a view of all resources involved in
production?
2. Are there overviews that allow
evaluation of the current
manufacturing situation?
3. Are the detailed planning functions
based on current data?
4. Does detailed planning manage
primary and secondary resources?
5. Is there a load planning function for
different kinds of secondary resources?
6. Can you model different possibilities of
technological relationships?
7. Is inter-order networking possible?
8. Can the types of capacity be varied?
9. Are different planning strategies
supported?
10. Can detailed planning instances be
evaluated by means of flexible and
combinable key data?
11. Can alternative planning variants be
simulated?
Quality
1. Can quality inspections be
incorporated like work operations
in the overall order structure?
2. Is there a dynamic configuration
function to monitor testing and
inspection equipment?
3. Is non-conformance management work Data Acquisition
flow supported?
1. Does the MES permit gapless automated
4. Is gapless traceability of the production
data acquisition and processing?
process possible?
2. Are standard interfaces provided to
5. Does production planning have access
machines and automatically controlled
to quality data?
machines?
6. Can process measurement data also be
3. Can all data acquisition functions be
used as quality characteristics?
configured for better ergonomics and
7. Is there support for automatic transfer
thus greater acceptance?
of measured data via standard interfaces?
4. Are standard data acquisition interfaces
such as OPC supported?
Personnel
5. Are the data acquisition functions
1. Is staff work-time logging with
available on different platforms, such
information and intelligence functions
as RFID, bar-code readers, and label
available at the terminal?
printers? 27
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Category
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Vendors
Vendor Name
Product Names
Functional Range
Industries Served
Apriso
FlexNet
Aspen
Technologies
aspenONE
Camstar
Systems
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Size of
Business
Served
Large
Vendor
Profiles
Databases
Supported
Platforms Supported
Delivery Mode
Microsoft SQL
Server, Oracle
On-premises, virtual
environment
Microsoft SQL
Server, Oracle
On-premises
Midsize
and large
Microsoft SQL
Server, Oracle
Microsoft
On-premises, SaaS
Midsize
and large
Microsoft SQL
Server, Oracle
Microsoft .NET,
Windows 64
On-premises
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CDC Software
Product
Comparison Tables
Category
Introduction
Technology
Landscape
How to Evaluate
Costs/ROI
How to Evaluate
Vendors
Vendor Name
Product Names
Functional Range
Industries Served
De Clercq
Solutions
Objective MES
Product
Comparison Tables
Size of
Business
Served
Midsize
and large
Databases
Supported
Vendor
Profiles
Platforms Supported
Delivery Mode
On-premises
Small,
Microsoft SQL
Microsoft Windows
midsize, Server 2005, 2008 Server 2003 and 2008,
and large
Windows XP, Windows
7, Windows Mobile,
Palm OS, Android
On-premises
IBM DB/400,
Microsoft SQL
Server, Oracle,
MySQL
eyelit MES
Midsize
and large
Microsoft SQL
Server, Oracle
Microsoft Windows,
Unix, Linux, and others
GE Intelligent
Platforms
Proficy Plant
Applications
Small,
midsize,
and large
Microsoft SQL
Server
Microsoft
On-premises
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Eyelit
Category
Introduction
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Vendors
Product Names
Functional Range
Industries Served
HighJump
Software
HighJump
Manufacturing
Advantage
Industrial mfg.,
automotive, aerospace,
food and beverage
Honeywell
Process
Solutions
Business FLEX,
Matrikon,
OptiVision,
Uniformance
Includes planning and scheduling, supply chain mgt., operations mgt., data warehousing,
integration and communications
iBASEt
Solumina
Intercim
Pertinence Suite
powered by
Velocity
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Size of
Business
Served
Midsize
and large
Databases
Supported
Vendor
Profiles
Platforms Supported
Delivery Mode
Microsoft SQL
Server, Oracle
Microsoft Windows
On-premises, cloud
Small,
midsize,
and large
Microsoft SQL
Server, Oracle
On-premises
Midsize
and large
Microsoft SQL
Server, Oracle
On-premises
Small,
midsize,
and large
Microsoft SQL
Server 2008 R2,
Oracle 11g
Microsoft Windows
Server 2008 (32/64bit), Windows XP
Professional, Windows
Vista Business, Windows
7 (32-bit)
On-premises
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Vendor Name
Product
Comparison Tables
Category
Introduction
Vendor Name
Invensys
Technology
Landscape
Product Names
How to Evaluate
Costs/ROI
Functional Range
Manufacturing
Includes electronic work orders,
Execution Module
BOM, product traceability,
operations standard functionality, inventory control
How to Evaluate
Vendors
Industries Served
Hybrid, process, discrete mfg.
MPDV
Mikrolab
GmbH
HYDRA
Parsec
Automation
TrakSYS
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Size of
Business
Served
Small,
midsize,
and large
Vendor
Profiles
Databases
Supported
Platforms Supported
Delivery Mode
Microsoft SQL
Server 2005,
2008; Oracle
On-premises
Midsize OLE-DB-compliant
and large
Midsize
and large
Microsoft SQL
Server
On-premises
Microsoft Windows,
Linux, Unix
Browser technology/Webbased
On-premises
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Performix
Product
Comparison Tables
Category
Introduction
Technology
Landscape
How to Evaluate
Costs/ROI
How to Evaluate
Vendors
Vendor Name
Product Names
Functional Range
Industries Served
Plex Systems
Plex Online
Oracle
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Vendor
Profiles
Size of
Databases
Business
Supported
Served
Small and SaaS/cloud-based
midsize
Platforms Supported
Delivery Mode
SaaS/cloud-based
SaaS
Oracle Solaris
x86-64 (64-bit)
On-premises, on-demand,
or hybrid
FactoryTalk
Scheduling, order mgt., quality Pharma, biotech, medical devicProductionCentre control and mgt., material track- es, CPG, food and beverage,
automotive
ing and mgt., WIP/Inventory,
workflow and performance mgt.
On-premises, SaaS
Midsize
and large
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Rockwell
Automation
Product
Comparison Tables
Category
Introduction
Vendor Name
SAP AG
Technology
Landscape
How to Evaluate
Costs/ROI
How to Evaluate
Vendors
Product
Comparison Tables
Vendor
Profiles
Size of
Databases
Business
Platforms Supported
Supported
Served
SAP Manufacturing Traceability, non-conformance High-tech, industrial machinery
Small,
Microsoft SQL
Microsoft Windows
Editorsmgt.,
Note:
This select
list of
ERP suppliers
is based
on market
reports,Server,
analyst
reports,Server,
and company
information.
Execution
production
transfer,
ERP
and components,
aerospace
andresearch
midsize,
Oracle
HP-UX, Solaris,
integration, return and repair,
defense, automotive, medical
and large
Linux, AIX
labor tracking, engineering
devices
change mgt., production metrics, globalization
Product Names
Functional Range
Industries Served
Ampla
Siemens MES
SIMATIC IT
Werum
Software &
Systems
PAS-X
Pharma, biotech
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On-premises
Microsoft SQL
Server, Oracle,
OPC DA, OPC
HDA, InSQL,
major SCADA and
historian systems
Microsoft, Java
CD
Midsize
and large
Microsoft SQL
Server, Oracle
On-premises, Web-based
Midsize
and large
Oracle
Flexible
On-premises
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Schneider
Electric
Delivery Mode
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Vendor Profiles
Selected Suppliers of Manufacturing Execution Systems
(In alphabetical order)
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Apriso
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Selected Suppliers of Manufacturing Execution Systems
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De Clercq Solutions
De Clercq Solutions has more than 10 years of
experience with the implementation and integration of MES setups. The companys MES
offering, Objective MES, starts with detailed
planning; it optimally controls operators and
machines, and analyzes performance and
quality.
The product dispatches work orders efficiently, taking into account the real capacity
and capacity utilization. Objective MES also
helps optimize resources. It monitors production and reacts to problems. The system also
supports maintenance activities and quality
management. Koen De Clercq is the CEO of
the company.
Emerson Process Management
Emerson Electric is a global leader in bringing
together technology and engineering to provide solutions to industrial, commercial, and
consumer markets through its network power,
process management, industrial automation,
climate technologies, and appliance and tools
businesses. The companys sales in fiscal 2009
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Selected Suppliers of Manufacturing Execution Systems
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iBASEt
iBASEt has been a leading provider of hightech software products and services since
1986. iBASEts MES product is called Solumina. The software is an Operations Process
Management suite that manages work and
quality processes for the manufacturing and
maintenance, repair, and overhaul of highly
engineered products. Solumina functional
modules include process planning, MES and
operations management, quality management, and supplier quality assurance in one
integrated system. The companys CEO is
Ladeira Poonian.
Intercim
Founded in 1983, Intercim, headed by CEO
John Todd, supports more than 100,000 users worldwide in a number of fields, mainly
advanced and highly regulated industries.
In 2009, Dassault Systmes took a minority
position in Intercim. Both companies believe
in real-time information exchange and collaboration between engineering, manufacturing, and the supply network. As a result
of the combination, Intercims MES software
product, Pertinence Suite powered by Velocity,
bridges the gap between product design and
the supply chain.
Pertinence Suite supports Lean, Six Sigma,
and other process initiatives. From simplified
process planning and advanced predictive
analysis to best-in-industry process execution
and quality management, Pertinence Suite is
designed to help manufacturers reach their
operational goals.
Invensys
Invensys PLC formed Invensys Operations
Management in 2009, when it merged six
long-standing branded product groups into
a single unit focused on meeting the manufacturing industrys need for comprehensive,
real-time operations management solutions.
Today, Invensys Operations Management, led
by President and CEO Sudipta Bhattacharya,
is a provider of automation and information technology, systems, software solutions,
services, and consulting to the global manufacturing and infrastructure industries. The
companys products are used by more than
40,000 clients around the world in more than
200,000 plants and facilities.
Invensys Operations Managements offerings are delivered under several prominent industry brands, including Avantis, Eurotherm,
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Parsec Automation
Parsec Automation, led by President and CEO
Eddy Azad, is focused on helping companies
rapidly improve the productivity of their factories. Parsec does this by providing TrakSYS,
an advanced and scalable manufacturingproductivity management software application suite.
TrakSYS is an extensible MES application
that is designed to aid lean, Six Sigma, TPM,
and operational excellence efforts for companies in many industries, including automotive,
chemicals, consumer products, construction
materials, electronics, food and beverage,
metals, mining, packaging, pharmaceuticals,
paper products, textiles, utilities/energy, and
wood products.
Performix
Performix, founded in 2005, develops products
for the batch process manufacturing industry.
Sham Afzalpurkar is Performixs CEO.
The companys suite of composite software
applications, Performix xMES, is designed to
leverage SAP technology and manufacturing
system infrastructure. Performix serves the
chemical, consumer products, food and beverage, and pharmaceutical industries. Performix xMES Suite is used by Dow Corning and
several leading pharmaceutical companies.
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Plex Systems
Since 1995, Plex has been a provider of online
software for the manufacturing enterprise and
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empowers businesses to reduce costs and improve production efficiency, performance, and
profitability. Amplas energy module supports
the identification and tracking of energy overconsumption based upon production context.
Ampla is used to identify bottlenecks, analyze
production downtime causes, calculate key
performance indicators, manage WIP inventory, track the real costs of production, and
manage other important operational performance issues. Ampla supports continuous
improvement projects to achieve operational
excellence.
Siemens MES
Siemens, founded in 1847, is a global leader
in electronics and electrical engineering, and
operates in the industry, energy, and healthcare sectors. With 405,000 employees in 190
countries, Siemens reported worldwide revenue of $104.3 billion in fiscal 2009. Siemens
in the USA reported sales of $21.3 billion in
the U.S. and employs more than 60,000 people
throughout all 50 states and Puerto Rico.
SIMATIC IT, Siemens MES product, allows
companies to implement a cross-plant technological solution for enforcing value-driven
strategies on the one hand and performance
measures on the other. SIMATIC IT, with its
open architecture, offers the collaboration
and integration technologies that allow
manufacturers to couple disparate systems,
support distributed manufacturing operations, and connect manufacturing operations
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Footnotes
Manufacturing Execution Systems Buyers Guide
1. Lhn, Johann. Government Commissioner for Technology Transfer, Baden-Wurtemberg, Germany, in the Foreword to Manufacturing Execution SystemMES. Jrgen
Kletti, Springer Publishing, Inc., June 27, 2007.
2. ibid, VI.
3. Cole, Brenda. Interest in Manufacturing 2.0 MES Software Persists Despite Recession, SearchManufacturingERP.com, May 27, 2010.
7. Flakol, Rita. MES vs. ERP: Is It All in the Jargon? Manufacturing & Logistics IT, Nov. 28, 2008.
8. ibid.
9. Khosrow-Puor, Mehdi. Emerging Trends and Challenges
in Information Technology Management. Idea Group, Inc.,
2006, p. 865.
10. Stratus Technologies. Manufacturing IT Infrastructure: Ready or Not for MES? White Paper, October 2006,
p. 3.
11. ibid.
12. The Association of German Engineers (VDI), VDI
Guideline 5600.
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(MES) Strategy Update: Must-Know Trends, SearchManufacturingERP.com Webcast, April 26, 2010, slide 2.
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