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Ask the Manufacturing Execution Systems (MES) Expert: Scheduling Assistance
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Evaluating TCO on MES

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How do we evaluate the cost/benefit of MES and which MES software is the best fit for our organization and industry? We use SAP, have purchased MII, and are trying to upgrade equipment and bring on-board an automated line. It has been challenging to research MES applications and find out the detailed cost/benefits and determine the sequence of implementation (equipment PLC's and SCADAs, Historian, MES, etc. – i.e., what should come first vs. what should drive the requirements for subsequent applications). All applications tout their benefits at a generic high level, but how do we learn about the best application for semiconductor, solar cells, and aerospace products, which we have a mix of. Are there companies using SAP, MII and MES applications in the semiconductor or solar cell manufacturing industry? If so, which ones? We would like to benchmark best practices and learn from companies that have the same combination of applications we consider implementing. Ideally, we would like to tour another facility similar to ours or at least in the same industry.

Brenda Teng, Sylmar, CA
AMES (often referred to as Manufacturing Operations Management, or MOM) is a “must have” for mid- to large-scale semiconductor and solar cell producers to expand and grow in market share. MOM is very necessary to characterize, optimize, and scale manufacturing operations processes to bring up volume and quality while maintaining low cost. Most big semi and solar players have implemented ERP with a separate set of MES/MOM solutions to handle complex factory workflows and short product lifecycles. Some utilize advanced process control systems to control physical plants, pipelines, complex tooling, and heating equipment. MOM best practices and benchmarks for semiconductor or solar industries are still not consolidated or developed to the extent where they describe how best to integrate semi and evolving solar equipment with MES/MOM systems. We strongly recommend engaging a qualified MOM consultant to provide the best insight due to the lack of real hard data or broad-based best practices studies.

We also recommend participating in MESA, ISA, SEMATECH, etc. to solicit best practices approaches through literature searches and networking with many MOM/MES end users from many end user companies in many verticals. As well, the Managing Automation site has another great resource in the TechMATCH feature to compare vendors based on the features. In particular, MESA publishes a number of guidebooks, research studies, and white papers as well as the yearly MES/MOM Product Survey, which explain a number of best practice evaluation approaches on how to do an MES/MOM Value Benefits Analysis. Please refer to www.mesa.org for further information. We strongly recommend the approach of utilizing a consultant as the best way to derive an informed decision and evenly weighted perspective. What is best for one company in an industry is not necessarily best for another. Invest in a discovery assessment followed by a more formal RFP selection process that invites a short list of vendors to demonstrate solutions to your documented needs. This gets you directly in touch with the most viable solutions and associated pros, cons, and compromises.

MES/MOM solutions have matured in the semiconductor industry over 20 years; MES systems are leveraged by most big producers to enable a make-to-order global supply chain. However, each vendor and system integrator has its pros and cons. Generally speaking, mature players tend to have very complete solutions on dated architectures that deal with very detailed semi production, but, on the other hand, are slow to adapt to newer software technologies and architectures. Their solution may be easier to implement, but harder to evolve in the future and more expensive to own. Newer players may not have complete solutions, but are flexible, generally cheaper to own, and take advantage of newer software technologies. These solutions take more customization initially, but also adapt to newer, specific requirements quickly.

AS an MES/MOM best practices organization, MESA does not endorse one vendor’s approach over another, but provides perspectives on various best-practice approaches. As not to show favoritism to any vendor and to show respect to the intellectual property of end users, MESA is not able to broker end user references except by facilitating networking within MESA by individuals and companies.

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MESA Technical Committee

The MESA Technical Committee is the technical arm of Manufacturing Enterprise Solutions Association (MESA) International. MESA is a worldwide not-for-profit community of manufacturing companies, IT system integrators, consulting service providers, analysts, academics, hardware and software suppliers, and students. Its purpose is to improve manufacturing operations through optimized application and implementation of information technology and best management practices. Over the last 12 years, the Tech Committee has produced many whitepapers and guidebooks while expanding to include the full range of manufacturing environments, from discrete to batch to process. The association’s efforts are focused on information technology that supports real-time production events and generates information that can be used to support broader company and value chain objectives such as lean manufacturing, collaborative supply chain management, regulatory compliance, etc.
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