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Request for Information

Manufacturing Execution System

RONAL AG

List of Content

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Introduction .................................................................................................................................... 3 1.1 1.2 1.3 1.4 Company profile...................................................................................................................... 3 Locations ................................................................................................................................. 3 Standard process step ............................................................................................................. 4 Specials.................................................................................................................................. 10

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Project information ....................................................................................................................... 11 2.1 2.2 2.3 2.4 Motivation............................................................................................................................. 11 Objectives.............................................................................................................................. 11 Project organization .............................................................................................................. 12 Project timing ........................................................................................................................ 12

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Basic functionalities ...................................................................................................................... 14 3.1 3.2 3.3 3.4 3.5 3.6 APS module Requirements ................................................................................................... 15 Visualization and Monitoring ................................................................................................ 15 Report ................................................................................................................................... 16 Traceability-Requirements .................................................................................................... 17 Human Resource ................................................................................................................... 17 Energy Management ............................................................................................................. 17

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System and Software Requirements............................................................................................. 18 4.1 4.2 4.3 4.4 4.5 4.6 4.7 General MES Requirements .................................................................................................. 18 Supported Systems and approved Standards ....................................................................... 20 Business continuity / Emergency requirements ................................................................... 21 Definition of required Interfaces .......................................................................................... 22 System Architecture .............................................................................................................. 24 User/Account Management and Permissions concept ........................................................ 24 Customizing/Personalization Capabilities ............................................................................. 25

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Implementation Concept .............................................................................................................. 26

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Italy.and Switzerland . RONAL stands for cutting edge technology. innovation and quality work. These principles are responsible for the continuous growth of the company. customer focus. RONAL has been focused for the past 28 years on the production of shower enclosures as well. In order to safeguard the highest quality. 1. The production of the tools takes place in both Portugal . Besides its production of wheels.1 Introduction This document describes the functional specification of Ronal as a request for information. it is able to work with competitive cost structures and it is able to serve its customers locally. RONAL's philosophy is centered around three principles. Härkingen also accommodates the Research & Development department and the headquarters of the group. creative design and uncompromising quality.Cantanhede . Czech Republic. Quality is RONAL’s philosophy. RONAL supplies and takes care of its customers directly from Germany. 3 . RONAL manufactures its own production tools. Mexico and the USA.Härkingen. This geographical and organizational structure secures short development times at the highest quality and know-how levels. Apart from the tooling department. RONAL was founded in 1969 and soon became one of the pioneers in the global market for light alloy wheels. Poland. 1. Spain.2 Locations Due to RONAL's international manufacturing network.1 Company profile RONAL is a leading manufacturer of light alloy wheels and shower enclosures.

1.3 Standard process step Process Melting Input Aluminum alloy AlSi7MG or AlSi11MG with about 600 – 900kg Aluminum chips from the production Scrap wheels Processing Pouring of the melt out of the oven to transportation ladle Preparation of melting cleaning with argon or forming gas  impeller purging Manpower 12 operators / 4 shift model Process in numbers Process temperature about 750°C – 785°C Energy demand about 110 – 1350 m3 gas/ton Output Aluminum melt of both alloys AlSi7MG or AlSi11MG Process Casting Input Prepared melting AlSi7MG or AlSi11MG in the ladle with about 850 – 1500 kg Wheel data via conveyer to the next process Compressed air for feeding of the mold and cooling of the air (8-16 cooling cycles) Filter for the melting (“oxide brake”) Processing Visual quality control Eliminate the casting fin Mold temperature about 485°C – 560°C Transportation via conveyer to the next production step Cycle times about 250 – 380 sec/wheel Raw cast weight about 9 – 35 kg Manpower about 5 operators per shift per 12 casting machines / 4 shift model Process in numbers Temperature of the melting in the casting machine about 680°C – 715°C step Output Raw cast wheel AlSi7MG or AlSi11MG 4 .

O.o.i. wheels to next process step n. Wheel data from the conveyer Allocated tool Processing Transportation with conveyer to the next process step Manpower about 4 operators per shift Process in numbers Cycle time about 30 sec/wheel Output Raw cast wheel degated 5 . wheels to scrap Process in numbers Cycle time about 40 sec/wheel Process Degating Input X-rayed wheel i.o.Process X-Ray Input Raw cast from the conveyer Wheel data from the conveyer X-Ray programs Processing Transportation with conveyer to the next process step High dynamic radio scope up to 30 pics/sec Manpower about 4 operators / 4 shift model Output Raw cast wheels X-rayed i.

O.Process FlowForming (FF) Input X-rayed wheels i.i. degated FlowForm tools FlowForm programs Processing Transportation via palette/conveyer to the heat treatment Wheel temperature during the process about 340°C Manpower 1 operator per shift Output Flow formed wheels i.o. wheels to next process step n.o.o. Output Wheels heat treated Partly wheel data via barcode Processing Transportation with conveyer/palette to machining Process in numbers Cycle time solution heat treatment about 280 min with about 540°C Quench hardening about 65°C Cycle time artificial aging about 180 min with about 155°C Manpower about 3 operators per shift 6 . wheels to scrap Process in numbers Cycle time about 60 sec/wheel Process Heat treatment Input AlSi7MG wheels X-rayed i.o. degated FlowFormed i.

Process Machining Input Wheels AlSi7MG or AlSi11MG Heat treated and FF in AlSi7MG Wheels AlSi11MG x-rayed i. wheels to scrap Output Machined wheels i.o.o.i. wheels leak tested/balanced to scrap Processing Transportation with conveyer/palette to deburring Manpower 1 operators per shift per line Process in numbers Cycle time 30 sec/wheel i. drilled. degated Wheel identification and machining programs Processing Transportation with conveyer/palette to washing and leak test Process in numbers lead time for the whole machining process steps about 6min//wheel Manpower 1 operators per shift per line n.o.o.o.i. wheels Output Machined wheels 7 . wheels (via drawing) (turned. balanced and pre-deburred) Process Balancing Input Machined wheels after washing and leak test with helium Programs for the balancing n.

Process Brushing / Deburring Input i.o. balanced manpower Processing Transportation with palette to surface finishing Output i. wheels deburred Formulation for painting Paint systems Processing Wheels direct via roller belt to finished goods control Paint layer intensity with 3-layer-paint about to storage to next production step 150 – 180 my Manpower about 15 operators per shift Output Painted wheels i. wheels to scrap Process in numbers Cycle time manual deburring about 2-10 min/wheels (depends on design) Cycle time brushing about 1 min/wheel Manpower 1 operators per shift per work station Process Painting Input i. wheels washed.i.o.o.o. leak tested. for rework or stripping or scrap Process in numbers Capacity about 500 wheels per hour 8 .o.i. wheels as customer specification n.o. wheels brushed and deburred n.

wheels painted to customer specification packaged and prepared for shipping 9 . Labels Instruction for logistic Packaging material and loading equipment Processing Shipment to the customer Process in numbers Manpower about 8 operators per 4 shift Output i.o.Process Storage/Shipping Input Wheels painted with quality control i.o.

wheels with basis 2/3-layer paint Process Multi Color Rim (MCR) Input Wheels painted 2-layer-base coat and contrast paint Front Facing-programs (turning programs) Mirror lathe Processing Transportation with palette to painting area for transparent finishing Process in numbers Manpower 1 operators per shift per machine Output Front Faced i. wheels with 2-layer-base coat and contrast paint Colored base coat appears at the Front Faced surface 10 .o.o.4 Specials Process Front Facing Input Wheels painted 2/3-layer-paint Front Facing-programs (turning programs) Mirror lathe Processing Transportation with palette to painting area for transparent finishing Process in numbers Manpower 1 operators per shift per machine Output Front Faced i.1.

control and trace. process and quality related process parameter in ONE consistent data base to visualize. Measured goals are defined: Traceability of the availability of machines Reducing of non-productive time o o o o o o Systematically change overs Increasing the OEE  Productivity.1 Project information Motivation The motivation of the project is to have a standardized conception of functionalities to control the production with each steps included. daily) Energy consumption (Co2-bilance) Maintenance - Documentation of down times. Optimized planning and control of resources (machines.2 2. lead times. Quality Management of production processes Accelerate of crucial production processes Harmonized manufacturing landscape Consolidation of applications To achieve the goals we need to gather all production. the quality and the process parameter Access control Reporting o o o o KPI’s Reports for production (monthly. scrap (on time during a production day) Planning of change overs during a production day Planning and documentation of manpower during a production day Visualization of the production (quantities) and process parameter o o o o Real time History Definition of borders – tolerances Warning function (signal/information/…) with overrun the borders Monitoring of the production. manpower) and processes o Visualization of production monitoring for control Traceability of a wheel (whole lifecycle from Aluminum purchase till shipping to customer) Optimized visualization of information (reporting) Control with production orders based on feedback of the production o Cycle times. 11 . machines and tools 2.2 Objectives The main goal is the increasing of the economics of scale with controlling the production based on measured values. Availability.

dates Choose of system provider 12 . costs.XPPS) Patrick Huber (IT Strategy) Rafal Karolewski (Support implementation in the 1 plant W06) Thomas May (Quality) Thomas Trampenau (COO) Manfred Wirth (Infrastructure) st 2.2. 3 supplier Clarify request (phase 2) o o o o o Adjustment of requests with the system provider Consulting o provider based on conception and implementation Definition of necessary investments contract specification with implementation guide.3 Project organization Orderer of the project is the Chief Officer Operation Thomas Trampenau.4 Project timing We defined different project phases with the timing for the first plant. The main steps are divided in sub steps Analyses and rough specification (phase 1) o o o o Definition of basic requests at MES Project draft --> request specification Long list based on „rough specification Reducing long list with defined criteria to short list – max. In the following picture are shown the main steps including the time line. Project manager: Ulrike Buchholz (Operations) Core Team consists of: Jacek Cyrwus (Plant manager) Holger Girmond (ERP .

- Detailed conception (phase 3) o o o o o o o Evaluation of quotation and selection of supplier for phase 3 Definition of detailed integration in existing IT-systems for data transfer of master data Definition of necessary configurations in the system (user admin. standard attribute Definition of evaluation Decision of the right system provider - Developments of system supplier Test environment o Define test environment – start and test in a small area - Realization of "pilot" (for each department) and training o o o o Training of defined staff Installation of hard.…) Definition of surfaces and layouts. e.g. rights. at gathering station Definition of basic conditions for corporate standards: standard inspection plans. … Preparation of standard reports and analysis - Implementation and active phase 1st plant o o o o o o Master data transfer Connection to existing systems for data collection Test planning Employee training Data collection Roll-out at plant - Business operation o o Regular business Maintenance and system maintenance - Review Roll-Out RONAL Group 13 . user surface. layouts.and software for "pilot" (reduced request) Integration master data Checkout of test environment (production environment)   o o Automatically data collection Manually data collection Adjustment and optimization of configuration.

Documentation Reporting Traceability Human Resource Energy Management The next chapters describe some of the functionalities in detail. One of the main integrated documents describes in detail the expected functions in form of a checklist. 14 . The Ronal MES is focused on the following main functionalities: APS Visualization and Monitoring o Includes also History.3 Basic functionalities Different main functionalities are defined and combined to MES-modules. Escalation. the others are covered in the checklist.

mid. to visualize the production situation and to visualize the ongoing production results and show the impact of them to the shop floor orders and the production situation. Also the system back up should be continuous. The main objective of the APS module should be the visualization of the ERP shop floor orders. All interfaces should be possible to change manually. graphs. 15 .g. This includes the following main modules and main processes (Not all modules and processes are used in its entirety and there are also differences in the use of these between the individual plants):         EDI communication with customers and suppliers Order processing for OE and AM customers Warehouse and revolving inventory management Material and (capacity) planning (MRPII) Purchasing procurement Production planning Shop floor order handling Data collecting and data feedback from the shop floor The APS module should be positioned as a detailed planning system for the shop floor. History There has to be the possibility to store/save historical data and have a constant access to them. Visualization It is very important.and long term production plan) and on the shop floor orders from the ERP system. charts and so on. Also important is to have some library with basic animations.3.2 Visualization and Monitoring Please note: The detailed requirements of the sub-functionalities can be found in the corresponding checklist. Ronal uses the ERP system Infor XPPS for the execution of all operational and economic aspects. which is based on the higher level planning data (e. 3. The visualization should be possible real-time and history. that the system is flexible and able to modify.1 APS module Requirements Please note: The detailed requirements of the sub-functionalities can be found in the corresponding checklist. the ability to schedule (within certain limits and boundary conditions) the shop floor orders in a more detailed matter. big screens located on production or even on tablets and Smartphones. There should be the possibility to show information not only on computer screens also on dashboards.

NC-programs. From the MES system we could get all the information we need to make a value stream map and generate it for each part There should be an easy way of generating and sending reports to different employees.g. Documentation This functionality should be able to administer programs. To analyze it is very important to have statistic tools and history record.g. e. There should be the possibility to define the reaction of a warning – e. stopping a machine or slowing down the process and so on. 3. Reporting uses the existing Ronal tools (EIS / EIP from aruba informatik GmbH). 16 .Monitoring The system should be able to monitor process parameter of machine status and the production process. also of the product quality. SQL) and can be analyzed. One helpful tool could be value stream mapping. We need to be able to analyze data in Excel as well.3 Report The solution provides data pools or cubes which come in a standard database format (e. Escalation There should be the possibility to define warn limits and reactions for each warning ( sound signalization.g. sending reports or work orders to declared employees) and also the kinds of reactions.

A unique identifier (serial number) printed on the casted wheel will be used for identification and allocation of data to each product during production process. As production results and quality information are gathered in local time zones. The traceability system will link the serial number to process and quality data including time stamp. groups and individual employees.4 Traceability-Requirements Please note: The detailed requirements of the sub-functionalities can be found in the corresponding checklist. 3. the traceability database needs to be using UTC time stamp. The MES system module “Traceability” enables RONAL to trace wheels in both directions. Definition: capability to trace a product from its origin through processing. The system should support with the calculation of bonus for workers according quality and quantity. For the management it is also important to have all employees and their schedules in one data base. considering parameters. It is possible to identify products by entering process or quality data or combinations of these (using Boolean expressions) and to receive all relevant wheels that have been produced during these conditions. The system should be able to generate reports. The system should make one base for working schedule and one for work orders. 3. delivery and receipt. The main functions are covered in the Ronal Energy Management System EMS.5 Human Resource Please note: The detailed requirements of the sub-functionalities can be found in the corresponding checklist. to its final location. 17 . the minimum level of traceability is defined as lot traceability and where applicable on a piece level.3. but partly functions has to be covered be the MES. back and forward.6 Energy Management Please note: The detailed requirements of the sub-functionalities can be found in the corresponding checklist. After entering a unique serial number it is possible. to identify the relevant process and quality data of that product and by linked XPPS shipment information to identify which customer has been supplied with this product.

IT Strategic Directions (Excerpt) • IT as Business Enabler • • • • overcome the “cost only” notion push/emphasize the strategic value/benefits demonstrate and deliver on promises Unify and Simplify • • Standardize and consolidate Reduce complexity • Optimization and Globalization • • “Global first”: whenever meaningful. System updates must not impact existing/already implemented configuration adaptations and customizations. global solutions and globalized systems will replace locally implemented solutions “Shared services”: instead of providing the same IT service multiple times per plant/country but in slightly different flavors. Different support scenarios and cases are clearly defined and have transparent SLA’s. the software update cycle has to be structured and needs to follow a clearly defined schedule.1 System and Software Requirements General MES Requirements Please note: for almost all of the described requirements the following paragraphs there is a corresponding section in the detailed checklist that has to be completed as part of this RfI process. stable. In order to achieve this the maintenance process has to be highly automated.4 4. support based on ITIL) System Maintainability Ronal aim at “least effort” maintainability.g. we will see more global IT services provided by one location for the whole group • Globalize IT Team and processes (e. Maintenance & Support The support processes are clearly and transparently defined and aligned with Ronal company structure and needs. 18 . This means that the ongoing efforts to keep the system secure. bug-free and current has to be minimal.

Deawoo.Volumes/Quantities for Server and Database Sizing Based on the process parameter documentation Ronal works with about 1023 process parameters in total. Fanuc. Danobat. The breakdown of the total is as follows:    Priority 1 (unimportant): 25 Priority 2 (important):114 Priority 3 (very important): 884 Taking prio2 and 3 together leads to rounded 1000 parameters multiplied by estimated 18 million produced wheels per year results in 18 billion records a year given that MES is in a fully deployed and productive status! Assuming one record is 10 kB (kilobyte) in size will give us an estimated yearly data volume of 180 TB (terabyte = 10 12 Byte = 1.000. Technology-wise this translates into Wintel and IBM iSeries hardware on the ERP/PPS side and full variety of PLCs (Siemens.000. The required integration is twofold: on one hand it is the office network with the superordinate ERP/PPS (primarily Infor’s XPPS) layer. Integration into existing IT Landscape The solution has to integrate seamlessly into the existing IT landscape. Hitachi etc. 19 .000 byte).000.) on the machine and automation side. Omron. on the other hand it is the production network with the subordinate machine and automation layer with its machine control (PLC).

as for all other already existing internal systems the same “usual” concepts.g. The only requirement . master-slave concept) have to be available and supported. using MS Active Directory as the central objects directory/repository. WAN: The Ronal locations are connected thru LAN-to-LAN VPN connections (over the Internet). required is an out-of-the-box integration with MS Office 2010 and Exchange 2010 (e.4. Historically there are still a few legacy protocols in use in some areas of some production networks. 20 .g. Client: Windows 7.as far as the MES solution is concerned – is that it doesn’t interfere with the existing system security concept and its applications. Hardware/OS Server: Priority 1: HP Intel with Windows Server 2008 R2. Ethernet and MPLS.x and higher) or DB2 on IBM/OS400. Connection types involve xDSL. for notification service). The various components which are part of this concept can be expected to be there and available. Some locations additionally have special purpose WLANs (e. optionally IBM iSeries with OS/400. rules and policies will be applied. All locations are shielded from the Internet by firewalls.g. FC. Bandwidths vary from 2 Mbps up to 100 Mbps. System Security Concept The MES solution will be another system within the Ronal corporate network boundaries. optionally Oracle (10. Supported database standards are: Priority 1: MS SQL (2008 and higher). Distributed databases (e. providing Internet access for non-Ronal visitors or wireless access points in production facilities). Usually the office and production networks are physically and/or logically separated for example by means of VLANs. Network LAN: All locations have Ethernet TCP/IP based LANs.2 Supported Systems and approved Standards Databases and data formats Due to data integrity reasons data records have to be stored in Unicode format. Most of the locations have a backup line in place however those capacities are minimal.

time-wise.g. As an accompanying feature we expect a full audit trail which keep track of all actions and activities that involve any MES application and data object. data history creation and keeping as well as data reorganization. In addition to what one can expect in this context on the facilities.Data Security Concept Data security is critical for the MES solution and comprises basically protecting a database from destructive forces and the unwanted actions of unauthorized users. 4. hardware. 21 . Data history. suppliers. archiving and reorganization The solution has functionalities for archiving. With his all modifications can be traced back. e.g. Centralized master data management Master data records (e.3 Business continuity / Emergency requirements High availability The solution is expected to support high availability solutions (application and database/ data storage layer). Backup/Restore Concept The MES data will not be treated differently than any other business application data if it comes to backup/restore. Defined data ranges and/or data fields (within a data range) can be administered on a per plant basis. Archived data is separated from productive („live“) data but still accessible by the so lution. for parts. customers) are centrally manageable within a tenant as well as cross-tenant (across the group). What we expect here is that the MES solution a) does work with any professional Backup software and b) the MES solution adds features that optimize the backup and restore process. OS and database level as means of addressing the potential issues (such as encryption or strong user authentication) we expect additional application based approaches to protect the MES database from data security breaches.

4. Interface to ERP The solution can work with a bi-directional interface to the ERP system.g. MS Office 2010 file formats can be handled by the MES solution and data can be imported and exported from/to MS Office 2010 and the MES solution.4 Definition of required Interfaces Data interfaces The solution comes with a variety of out-of-the-box interface options. Text (ASCII). Data Entry Interfaces The solution provides interfaces with which manual data feedback from various other systems (e. Data import and export have to happen in a manual and automatic way (batch and sequential recurring). Data which is not provided by the ERP system can be maintained as master data in the system and has to be linked to the data from the ERP automatically. final goods inspection etc. Office Integration The solution offers out of the box MS Office 2010 integration. so that this data does not have to be captured into two systems.g. The interface from the ERP system (ERP to MES) should handle following data: Parts master Tooling and additional equipment master Machine and work center master Production orders header Work cycles Material information (BOM) Machines and work centers Tools and necessary equipment 22 . The system can work with all parameters from the ERP system which are related to planning and scheduling of production orders. CSV. ODBC und LDAP have to be supported as a minimum. final goods inspection: Touchscreens are directly linked to a MES module). This means for example MS Office 2010 applications can be directly launched from within the MES solution. XML.) can be integrated into the MES or with which these systems can directly be connected to the appropriate MES functionality (e.

Machine status (setup. rework rates.Planning results (start date. Interface to Resource/Shift planning The solution provides interfaces systems and is able to work with the shift model systems which are maintained in the HR-Systems and is able to work with the daily time attendance and absence records. maintenance) .Actual production numbers per machine. rates.O. other interfaces (e. machines etc.) Interface to Maintenance system The solution provides an interface to Ronal’s maintenance system EAN. Staff and shift master data should be used from the existing systems wherever the necessary data is maintained in these systems (HR and Time attendance systems). The web client muss has to run on Internet Explorer 9 and higher.The interface to the ERP system (MES to ERP) should handle following data: .Actual production cycle times . Information which is send to the maintenance system is for example (detailed data requirements have to be defined in a workshop phase): .g. Machine (Controls) Interfaces The solution should be able to handle and work directly with data from machine controls. RS232) and other data capturing devices. end date. production. scrap rates) .Actual production rates (i. mold or any other tool Interface to Energy Consumption The solution provides an interface to Ronal’s Energy Consumption S ystem EMS. User Interface The user interface has to be available as a „fat client“ (local installation) as well as a web client (web browser) with identical sets of functionality and feature. CAQ/QA/QM Interfaces The CAQ interfaces are covered in the RFI of the CAQ-project. inspection. 23 . OPC’s.

in production one or the other topology approach will be deployed. non-Ronal) parties (such as e. Security requirements / Role and Profile Definition Access to and permissions within the solution are controlled by a granular permissions concept and model which supports multiple detailed access groups and levels down to field level. presentation) concept in a distributed system landscape. suppliers. Preferred is ESX/VMware and optionally HyperV/MS. logic. Application architecture The application architecture offers a 3 layer (data. escalation and other workflow purposes is key in order to automate recurring work items. The main focus is on the data and logic layer (hence application and database server). User credentials (user ID and password) have to come from AD. Modular structure The solution comes with a modular structure. Multi-tenancy The solution supports a multi-tenancy concept. Access for external (i. activated and used module by module. Hence the individual modules can be licensed. and LDAP). Within a tenant several plants/sites can be managed / administered. 4. Virtualization is supported.e.5 System Architecture System structure and landscape Concerning “Installation topology” the solution offers both: one centralized installation (all locations work on this single infrastructure) and the option to work with decentralized installations. The layers are logically separated from each other. IWA. As for internals access (where) and permissions (what) can be granularly assigned by using groups and/or roles. customers) has to be possible. Application permissions can be granularly assigned and administered with a role-based concept.6 User/Account Management and Permissions concept Active Directory Integration is required (Integrated Windows Authentication. 24 . Workflow functionalities Availability of a flexible workflow engine that allows the dynamically define chains of activities for routing. implemented.g.4.

This comprises but is not limited to:      Addition and deletion of predefined parameters. The language can be selected on a per user basis. Communication languages are German and English. Operating hours have to be based on local time zones. Licensing The solution offers flexible and creative licensing options which cover Ronal requirements. views and filters and functionality (e.e.7 Customizing/Personalization Capabilities The solution offers flexible and easy to use customization features.g.g.g. Languages The solution supports the following languages:         German English Spanish Portuguese Italian Czech Polish Simplified Chinese Additional languages are provided by the supplier or can be implemented/made available by means of simple translation tables or the like. 25 . fat and web client are identical) System updates are without impact on content and implemented adaptations of configuration Offline capabilities In case of network interrupts the solution has to continue to work in an “offline mode”. The language versions of the user interface and the outputs (e. the printouts are in English). interfaces to databases and other applications) Changes per GUI or script and command line possible Configurable toolbar and menu for end user Dialog and functionality changes in application equally and automatically implemented in web interface (i. escalation. for suppliers or customers) are printed in the supplier or customer language which is defined in the (supplier or customer) master data record. printing) can be separately managed and administered (example: users work with German user interface. Any of the other mentioned Ronal languages is an asset.4. In particular concurrent user licenses have to be supported. fields. Printouts for external parties (e. Hotline The supplier has a central hotline.

Once W06 is stable (and as such the pilot is completed) MES is going to be rolled out plant after plant. GHG emission Maintenance Downtime Machine Life cycle of tools Administration of NC-Programs Prio. MES core functionality means those functionalities that are mandatory and absolutely required to run the production in the new plant. wage calculation) Reporting KPIs. OEE Production Report (monthly report) Daily production report Flexible reporting creation Energy consumption. 26 . within a production day Controlling of production orders based on real time feedback (e. cycle times and scrap rates).g. W06 B B B C C C B B A B B B B C C C C C C C B After this initial start and “optimization phase” of approx. This set of functionality is referred to as priority A features Functionality Scheduling of production orders Visualization of manufacturing situation and progress (scheduling). The sequence and timing still has to be determined.g. e. 6 months will follow to stabilize the initial setup and to add additional (B and C) functionalities.g. within a production day Scheduling of change over on shop floor within a production day Allocation of operators / staff within a production day Wheel traceability Visualization of process parameters (real-time and history) Monitoring process parameter of machine status. manufacturing process.5 Implementation Concept st Phase 1 (“the pilot”) will comprise the implementation of MES core features in the new Ronal plant W06 in Walbrzych/Poland which goes live on 1 April 2013. Monitoring of product quality Possibility to define warn limits for the process parameters and notification Access to PLC (control) Performance counter per employee (e.