Presentation on MES-Trends and Opportunities

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MES/CPM Trends and Opportunities

Plant Software Plays A Key Role in Manufacturing Innovation

Greg Gorbach

Vice President

ARC Advisory Group

ggorbach@arcweb.com

ARC Forum,
Pune
, August 2011

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Topics


Trends


MES, CPM, and MOM


New MES Requirements


Manufacturing Operations Management


The Players


Purchase Criteria

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Macro Trends Driving Today’s Industrial
Ecosystem

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Today’s Business Environment

Makes Innovation and Responsiveness A Necessity

Business Environment


Power of Emerging Economies


Global Competition


Rise of the Millennials


Barriers to IT Access Falling


Dwindling
Resources


Increasing Energy Cost


Water Scarcity


Recycling, Disposal


Climate Change


Social Responsibility


Increasing Regulations


IT
Security


etc.

Differentiators


Quality


Branding


Product Innovation


Product Design


Traceability, Product Info


Process/Service Innovation


Response Time


Technology


Localization


Green


Value Networks


Anti
-
Counterfeiting


Price


etc.

1.

2.

3.

4.

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Impact


Competition for tech savvy
workers


Need to manage complex
network of suppliers,
partners, customers


New competitors entering
the market


More consumer power


Online ratings


Collaborative buying


Increasing cybercrime


More customization


New business processes
will emerge


etc.

IT Trends


Cloud computing


Mobility


Internet of things


Continuous Services/Connected
Devices


Cybersecurity

threats


Virtualization


In
-
memory computing


Openness


Ease of use


Reduced cost


Social networks


Ease of communication


Accessible, powerful analytics


etc.

3. Accessible IT

Will drive and enable manufacturing ecosystem changes

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2011: A New Perspective

Next Decade Will be About Empowering Value Networks

+

= Transformation
of Manufacturing

Plant
-
Centric,
Integrated

Value Network
Collaboration

Shifting
Economic
Power

+

Changing
Demographics

From:

To:

+

Resource &
Environment
Drivers

Powerful
New IT
Capabilities

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Collaborative Value Network (CVN)

Focuses on Activities Throughout the Value Network

Design

Production Network

Logistics

Distribution

Purchasing

Service

Sales,
Retail

Customers

Supplier Network

Engineering

Construction

Plant & Equipment

Product & Plant

In order to compete
effectively, better IT
tools are being utilized
throughout the value
network to speed and
optimize innovation,
production, and

delivery of goods

and services

Today manufacturers
operate within one or
more networks of
companies that work
together to provide
goods and services

to end consumers

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New
MES
Requirements

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Industry

Classic MES

New Requirements

Semiconductor

Complex Routing, Resource
Allocation, Quality, WIP Tracking,
etc.

Visibility, Analytics/Decision Support, Outsourced
Manufacturing, Business System Synchronization,
KPIs, Performance, Change Mgmt, Security,
Electronic Manufacturing History etc.

Pharmaceutical

Compliance, Quality (Direct and
Enforce Production), Electronic
Batch Records, Electronic
Signature, etc.

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Collection of Apps: Optimization,
Historian, Advanced Process
Control, etc.

Visibility, Analytics/Decision Support, Outsourced
Manufacturing, Business System Synchronization,
Performance, Change Mgmt, Security, Electronic
Manufacturing History, etc

A&D (Complex
Discrete)

CAPP, Quality, Resource Allocation
(Operators, Workstations, Tooling,
etc.) WIP Tracking, Traceability,
Work Instructions, NCR Resolution,
etc.

Visibility, Analytics/Decision Support, Outsourced
Manufacturing, Supplier Quality Mgmt, Change
Management, Security, Electronic Manufacturing
History, etc

Automotive
Supplier

Quality, Resource Allocation
(Operators, Workstations, Tooling,
etc.) Work Instructions, Just
-
in
Sequence Manufacturing/ Packing/
Shipping,
Error
-
proof
Packout

and
Labeling, etc.

Visibility, Analytics/Decision Support, Orchestrate
Inventory Replenishment by Operation,
Traceability and Recall Management, Business
System Synchronization, Performance, Change
Mgmt, Security, Electronic Manufacturing History,
etc

Automotive OEM

Visual Alarms, Stack Lights, and
Marquees, Line Control &
Broadcasting, Supplier Component
Sequencing, etc.

Visibility, Outsourced Manufacturing, Global
Manufacturing, Business System Synchronization,
Performance, Change Mgmt, Security, Electronic
Manufacturing History, Traceability and Genealogy,
etc

Today’s Dynamic, Demanding Environment

Places a Premium on
Information

and
Synchronization

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Contemporary Plant Software Topics

Manufacturers need a path to tomorrow’s solutions


Operations Platform, Integration


Visibility, Analytics, Intelligence


KPIs and Metrics


Workflow, Business Process Mgt


Security


Mobility


Innovation


PLM Integration


Quality Management


Materials Movement Integration


Traceability


Collaboration/Social Computing


SaaS
, Cloud Computing

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MES, CPM, and
MOM

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MOM

includes EAM, LEAN,
QMS, RPO, LIMS,
EH&S, HMI*, Software
Platform, etc.

Manufacturers’ Needs Extend Well Beyond
Traditional MES Applications

Enterprise &
Business Network

Line/Plant

Increasing Functionality

Performance

CPM

includes EMI, SPC,
Historian, CAPA,
Recipe
Mgt
, etc.

MES

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Manufacturing
Operations
Management

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Operations Management

Operations Management

Production
Management

Inventory
Management

Business
Integration

Maintenance
Management

Regulatory
Compliance

Energy
Management

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Operations Management Definition:


Operations Management
is the management of the people,
business processes, technology and capital assets involved in:


Procuring and receiving raw materials and components

-
Especially as it relates to obtaining, storing, and moving
necessary materials/components in a timely manner and of
suitable quality to support efficient production


Implementing product designs, specifications, formulations,
or recipes by manufacturing product
s

-
Including manufacturing process planning and validation


Distributing these products to customers

-
Especially as it relates to sequencing and in
-
house logistics


And for some products, supporting them through their End
-
of
-
Life

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What’s Needed?

A Holistic IT Approach to Managing Operations

Modern Platform

Broad Connectivity
& Synchronization

Comprehensive
Application Suite

Operations Management =

Source: ARC Advisory Group

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Components of a Comprehensive Plant
Floor Solution

Plan

Operate

Inform

Processes

Integration

Supply Chain

Engineering

Business

Controls & Equipment

Platform


Real
-
time Plant Capable


Technology Platform


Applications Platform


Business
Process
Mgt


Security


Role
-
based Portals


Unified Data


Integration
Engine


Change Management


etc
.

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Manage Production Processes

Use Detailed, Industry
-
Specific List for System Selection


Schedule


Processes


Data and Test Needs

Plan Production


Enforce Processes


Guide Operators


Collect Data

Execute Production


WIP Tracking


Electronic History


Traceability & Genealogy

Track Product Data


Role
-
based Views


Drill
-
down & Analytics


Event
-
triggered Notification

Inform & Analyze


CAPA


NCM


Supplier Quality

Enforce Quality


WMS


Line
-
side


RFID

Move & Store Inventory


Maintenance & Repair


Work Orders


Synchronize w/Operations

Manage Assets


RMA


MRO


Recovery & Recycling

Support Product thru EOL

Processes

Examples

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Operations Management Systems

Global Perspective

Enterprise IT S/W Infrastructure


Different Automation Systems


Different ‘MES’ systems


Different Automation Systems


Different Software Systems

Operations IT S/W Infrastructure

Global Business Needs:


Inventory visibility


Compare plants


Balance production


Standardization


Best Practices


Carbon compliance


S/W maintenance & rollout


etc

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Design/Engineering Infrastructure

Global Manufacturing Operations

Enterprise Infrastructure

Operations Infrastructure

= Manufacturing Node

= Design Node

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Custom Integration

Operations

PAM

LIMS

CPM/Automation

Data

TMS

WMS

Equipment

Operations Apps
Platform

PDM

P&IDs

Models

Equipment

Specs

Drawings

Eng. & Design Apps
Platform

Enterprise Apps Platform

CRM

SCM

FIN

ERP

EAM

Content

Technology
Platform

Eng & Design

Enterprise

Technology
Platform

Technology
Platform

A 3
-
Platform Architecture

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LEAP Manufacturing

Technology and Business Practices for World
-
Class Manufacturing

MES/MOM is Essential For Each Component: L E A P

L
eading
-
edge


Innovative


Technology
-
forward


Mobile, Social, Cloud, Model
-
based, Virtual, PLM, MES, etc.


Collaborative,

Integrated


Performance driven

E
fficient


Profitable


High Quality


Compliant


Safe & Effective


Local/Regional

A
gile


Responsive


Collaborative, Networked,
Pull
-
based, Interactive


Flexible, adaptive,
changeable

P
rogressive


Sustainable


Energy, Carbon,
Social, Water, Waste,
Closed Loop


Responsible

LEAP

Mfg

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LEAP Manufacturing

Leverages Innovative IT and Business Strategies

MES/MOM is a Key Vehicle to Take IT Innovations
Into the Plant

SC

ERP

PLM

MOM

Enterprise
Platforms

Value Network
Collaboration

Business
Strategies

Cloud

Mobile

Social

IT
Innovation

Analytics

Virtualization

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The Players

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MES/CPM/MOM Supplier Category Matrix

Category

Objectives

Themes

Products

Status

MES Suppliers

e.g.
Camstar
,
iBASET
,
Apriso, VIA
-
IT, etc.

Grow in Core
Industries &
New Energy
Tech

Performance,
Compliance, Quality,
Dist’d

Mfg, Ops
platform

Enterprise Platform,
Solumina
,
FlexNet
,
MAN
-
IT, etc.

Many continue to
grow

Automation Suppliers

e.g. Rockwell, GEIP,
Siemens,
Aspentech
,
IOM, Schneider, etc.

Own the Shop
Floor; Process &
Discrete;

Targeted
expansion

Control System
Integration,
Dist’d

Mfg, Interoperability,

Sustainability

FactoryTalk
,
Proficy
,

SIMATIC IT, WW MES,
etc.

Growth thru
acquisition slowing

ERP Suppliers

e.g. SAP, Oracle, CDC,
Plex

Systems

Own the Shop
Floor;

Own the
Infrastructure

Collaboration,
Performance, Agility,
Lean,
Dist’d

Mfg

SAP MII, SAP ME,
Oracle Shop Floor,
Fusion;
Plex

Online
(
SaaS
)

Strong performance

Infrastructure
Suppliers

e.g. Microsoft, IBM ,
Cisco, (with SAP,
Oracle)

Own the
Infrastructure

Collaboration,
Performance, Agility,
Dist’d

Mfg

BizTalk;
WebSphere
;
NetWeaver
; Fusion

Microsoft
succeeding thru
partnering

PLM Suppliers

e.g. Siemens PLM,
Dassault, Oracle, etc.

Own the Shop
Floor;

End 2 End PLM

Innovation, Supplier
Collaboration

Teamcenter
,
Tecnomatix
, SIMATIC
IT;
Intercim

products

Growing integrated
solutions

SC Suppliers

e.g.
HighJump
, Red
Prairie

Penetrate Shop
Floor

Inventory
Management

Manufacturing
Advantage,

Manufacturing
Execution

SC sector is
stressed

Technology/Toolkit
Suppliers

e.g.
Savigent
, Ninety
-
Five

Penetrate Shop
Floor; OEM their
technology

BPM, ISA
-
95, etc.

Catalyst, Easy95

Tiny

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CPM
-
D Market Leaders for 2010

0%
4%
8%
12%
IBM SiView
MPDV Mikrolab
IBS AG
Oracle
Apriso
Invensys
Rockwell Automation
Siemens
Camstar Systems
SAP
Applied Materials
2010 = 1073.7 Million US Dollars

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CPM
-
D Revenue Growth

CAGR = 11.7%

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Purchase
Criteria

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How Do I Justify Plant Software?

Plant IT is Necessary and Cost
-
Effective



Cheap Energy



C桥慰 坡瑥r



C桥慰 坡獴W




‘Free’ Emissions




Predictable Raw Materials




Available Talent Pool



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YESTERDAY:



Energy Cost Swings



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Expensive Emissions




Unpredictable
Raw Materials




Limited Talent Pool



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䍨敡C 卯ftw慲攠慮搠䥔

TODAY:

Manufacturing Software
is an

Essential
Tool
for
Agility,
Compliance,
and Cost Control

Cost

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© ARC Advisory Group

CPM Purchase Criteria


Fit for Purpose


Industry requirements, manufacturing model,
specific functionality, performance,
scability


Corporate strategy


high volume? Rapid
Response? Innovative products?


Legacy systems


Technology strategy


architecture, operation
system, policies or standards, multi
-
plant, etc.

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CPM Purchase Criteria (continued)


Supplier Qualifications


Maturity


Capabilities


Implementation, training, maintenance, etc.


Size


Industry experience, references


Local support

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CPM Purchase Criteria (continued)


Implementation and Support


Up to 3x to 5x software cost


Usually with a SI partner


Best practices, training, etc. by supplier


Methodology, strong deployment team, track
record, global reach


Support for issues, bugs, feature requests, etc.

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CPM Purchase Criteria (continued)


Pricing


Generally, one
-
time fees associated with
software licenses plus recurring fees for
maintenance and support


Per user, per site, per server, per enterprise or
some combination.


SaaS



monthly fee, not especially low, but predictable


Per
-
user, with a
mininimum

number of users


Additional fees for extra storage or bandwidth


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© ARC Advisory Group

Final Thoughts

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LEAP Manufacturing

Technology and Business Practices for World
-
Class Manufacturing

L
eading
-
edge


Innovative


Technology
-
forward


Mobile, Social, Cloud, Model
-
based, Virtual, PLM, MES, etc.


Collaborative,

Integrated


Performance driven

E
fficient


Profitable


High Quality


Compliant


Safe & Effective


Local/Regional

A
gile


Responsive


Collaborative, Networked,
Pull
-
based, Interactive


Flexible, adaptive,
changeable

P
rogressive


Sustainable


Energy, Carbon,
Social, Water, Waste,
Closed Loop


Responsible

MES/MOM is Essential For Each Component: L E A P

LEAP

Mfg

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© ARC Advisory Group

LEAP Manufacturing

Leverages Innovative IT and Business Strategies

SC

ERP

PLM

MOM

Enterprise
Platforms

Value Network
Collaboration

Business
Strategies

Cloud

Mobile

Social

IT
Innovation

MES/MOM is a Key Vehicle to Take IT Innovations
Into the Plant

Analytics

Virtualization

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© ARC Advisory Group


Operating
Excellence


Enterprise Visibility & Control


Quality, Flexibility


Efficiency & Cost Control


Asset Performance


Energy, Resource, Mgt


Risk Mgt & Safety

Execution


Dynamic

Value Creation


Collaboration


Business Innovation


Product Innovation


Mfg Process Innovation


Marketing

Innovation


Governance

& Compliance


REACH


Emissions Mgt


Carbon Tracking


21CFR part 11


MTSA


etc

Compliance

Drive Manufacturing Performance

Three Business Imperatives for a Changing Marketplace

Plant Software
is a Critical Tool

for
Achieving Enterprise Performance

Be Effective

Be
Proactive

Be Responsible

Optimize
Performance

Extend & Transform
Current Business

Support Corporate
Citizenship

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Thank You

For more information, contact the author at
ggorbach@arcweb.com or visit our web pages at

www.arcweb.com