SGARIEI

Technical Survey to develop a MES.

  • A technical survey for a Manufacturing Execution System (MES) project consists of a comprehensive process of surveying, analyzing, and documenting the current state (As-Is) of the production plant. Its objective is to understand how work is done today in order to define in detail the technical and functional requirements of the new system, ensuring its correct implementation and integration with the existing infrastructure.

  • This process is fundamental to avoid technical surprises and additional costs, connecting floor automation (OT) with business management (IT).

  • The main components are detailed here:

  • 1. Process and Flow Mapping (AS-IS).
  • • Workflow Mapping: Documenting how production flows from raw materials to finished product.
  • • Identification of Activities: Record operational tasks, manual steps, data collection, quality control and machine downtime management.
  • • Information Validation: Confirm with the actual operators and supervisors (not just managers) that the documentation reflects daily reality.
  • 2. Inventory of Infrastructure and Connectivity (OT - Operational Technology).
  • • Machinery Review: List the production equipment, PLCs (Programmable Logic Controllers), sensors and actuators.
  • • Communication Protocols: Identify which protocols the machines use (OPC UA, Modbus, MQTT, Ethernet/IP, etc.) for data extraction.
  • • Network and Connectivity: Evaluate the industrial network coverage on the production floor and the need for new cabling or Wi-Fi installations.
  • 3. Systems Integration (IT - Information Technology).
  • • ERP/SCADA/PLC: Define the connection points of the MES with the ERP system (for production orders) and with SCADA or PLC systems (for real-time data).
  • • Data Formats: Identify the formats and frequency with which information will be exchanged.
  • 4. User Requirements and Functionalities.
  • • Interviews and Working Groups: Meeting with end users (operators, supervisors) to understand their real needs.
  • • Definition of KPIs: Identify the key performance indicators (OEE, downtime, quality, efficiency) that the MES should measure.
  • • User Interfaces: Define how operators will interact with the system (touchscreens, tablets, PCs).
  • 5. Final Documentation (Deliverables).

  • The process concludes with the creation of the User Requirements Specification (URS), which includes:

  • • Process diagrams (workflows).
  • • Detailed technical inventory.
  • • Project scope (which areas will be digitized).
  • • Gap Analysis between the current and desired process.

  • In summary, a good technical survey answers the following questions: What machines do we have? How do they communicate? What data do we need to extract? And what manual processes should we digitize?


  • DATA:

  • To successfully implement a Manufacturing Execution System (MES), it is crucial to collect accurate, real-time data that allows control of the manufacturing process from raw materials to the final product.

  • The essential data to be collected can be divided into several functional categories:

  • 1. Production and Operations Data.
  • • Production orders: Planned quantities, start and end dates, and task sequencing.
  • • Cycle times: Exact record of how long each stage of the process takes.
  • • Inventory data: Movement of raw materials, work in process (WIP) and finished products.
  • 2. Machinery and Equipment Data (OEE - Overall Equipment Effectiveness).
  • • Machine status: Operating time, downtime and causes of downtime.
  • • Process parameters: Temperature, pressure, speed, etc., that affect quality.
  • • Maintenance: Incident log and preventive/corrective maintenance.
  • 3. Quality Data.
  • • Inspection record: Measurements and tests carried out during production.
  • • Non-conformity management: Data on defective products or rejections, including root causes.
  • • Traceability: Association of the materials used with the final product and the operator.
  • 4. Human Resources Data (Labor).
  • • Operator log: Who is operating each machine.
  • • Working times: Start and end of the workday, and actual activity times on the machine.
  • 5. Quality and Registration Data.
  • • Traceability and Genealogy: Documenting which component was used in which product and when, fundamental for quality management.

  • To ensure successful implementation, the data must be accurate, useful, and reliable, and the collection process must not be excessively expensive or time-consuming.

  • Additional Requirements:
  • List of processes.
  • List of procedures.
  • List of machinery.
  • List of machines.
  • List of systems.
  • List of departments.
  • List of personnel.
  • Customer list.
  • List of roles.
  • List of production lines.
  • List of production plans.
  • List of main faults.
  • List of current problems.
  • List of losses.
  • List of kpi's Main departments.
Money transfers.
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