INDUSTRY 4.0 MES/MOM
What is MES/MOM Software?
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Manufacturing worldwide is on the verge of a major transformation. The benefits derived from production are increasing day by day thanks to newly developing technologies.
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In modular smart factories, the goal is to monitor physical processes with cyber-physical systems, enabling objects to communicate with each other (IIoT) and with humans, thereby facilitating decentralized decision-making. These innovations, described as the fourth industrial revolution, will impact all industries. The general name for this system is Industry 4.0, or Smart Digital Factory . So, what will we gain from Industry 4.0?
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With Industry 4.0, the era of Digital Smart Factories is initiated, all activities are integrated and interconnected, systems communicate with each other, perform analyses, eliminate wasted time and unnecessary downtime, smart supply chains are established, and just-in-time production and flawless inventory management are achieved.
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Establishing an Industry 4.0 platform involves collecting and evaluating data from machines in real-time/online, and developing the building blocks of this platform : OEE Monitoring and MES (Manufacturing Equipment Software).
Many companies, mostly domestic ones, claim to be the best in the MES (Mechanical, Electronics, and Electrical) sector, using marketing language that includes terms like AI, predictive maintenance, self-learning systems, Big Data, Deep Learning, and the dark, intelligent factories of the future. However, they fail to explain the actual process because they lack expertise in this area. In this article, I will describe a real MES and its most important component, the OEE (Overall Equipment Effectiveness) infrastructure, with supporting documentation.
The table above is a weekly GE Proficy OEE report from 2012, taken from actual automation machines. Here, all the main automation machines have a remarkably high OEE value of over 85%, competing with top-segment companies worldwide. These are German-designed automation machines with all equipment from A to Z, controlled by very advanced Siemens PLCs.
Industry 4.0
How was GE Proficy-Intelligent Platform established?
How to Monitor OEE with GE Proficy MES Solution:
PLC Data Collection
GE operator Quickpanels were used to collect data from PLCs (panel screens were designed).
Over 10,000 Siemens PLC error codes were processed in GE Historian by communicating with OPC servers and receiving information messages.
The data was stored and filtered in Historian.
MES Software - GE Proficiency Plant Application
System modeling was performed in Plant Application.
Process reporting has been prepared in Proficy Portal.
It was applied to all (13) of the socket and switch automation machines.
Within the scope of Industry 4.0, IT-related server and hardware installations were carried out.
A GE Proficy MES system and reporting software compliant with the ISA-95 standard were designed and installed.
OEE reports and Fault Analysis
The system's data exchange channels with the existing ERP system were established in collaboration with IT.
The project group will design and develop the entire system, controlling the PLCs to be used via an OPC server.
By collecting the defined information from sensors via Profibus/Profinet or other protocols and transferring it to the GE Historian database, the software automatically generates OEE reports and Fault Analysis reports through filtering.
To be continued....
