Modern Manufacturing Operations Management and Supporting Manufacturing Execution Systems Focus on Optimising Operational Efficiency and Profitability
Manufacturing operations management (MOM) is the art of setting the policies and rules necessary to maintain production value and ensure that everyone and everything operates accordingly. It involves the continuous improvement of inventory, production, quality control, maintenance, and staffing around strategic objectives such as cost reduction, product innovation, sustainability, quality, and regulatory compliance.
MOM is delivered by applications such as Manufacturing Execution Systems (MES), which digitally transform operational processes and information to enable both efficiency and transparency in the following areas:
You can approach MOM from an equipment and production performance perspective only, or can evolve to maximum MOM functionality, integrating different operational domains through business process automation. They can implement MOM locally or can digitally capture and standardise processes, KPIs, and best practices for enterprise deployment.
Redefining Manufacturing Operations Management
Better management of industrial operations can have significant business benefits. Many companies, however, continue to rely on less efficient but more familiar manual approaches. However, when analysed, manual approaches are too inconsistent and isolated, and prove to be terribly inefficient. Collaboration is also difficult with traditional methods, and when experts retire or change jobs, their expertise goes with them.
MOM and supporting MES software have made great strides in bringing order to the plant, but unless they are easy to use and model the real-world dynamics of the plant, they may not achieve their fullest potential. Traditional MOM/MES approaches can also be very rigid, locking in procedures that may become obsolete the day they are implemented. And if you need to make changes to capitalise on emerging business opportunities, you may be out of luck.
Model-driven MOM is different. It encompasses everything in the MOM/MES world, but raises it to a new level of effectiveness. It uses a unique approach to model the real-world interactions between your physical plant, your processes, and your people. It provides a core set of templates tuned to your operations and an easy-to-use engineering environment that empowers you to refine and adapt easily, without need for coding.
A Closer Look at Model-Driven Operations Management
Manufacturing Operations Management defines activity between the basic plant control system and the plant floor in terms of relationships among business rules, physical equipment, and user interfaces.
System Platform provides a real-time, plant-wide platform, which MES applications can use to blend human and automated activity in the execution of standardised business rules and processes.
Workflow Management software pulls reusable, model-compliant procedural components from multiple applications and applies them for operational execution, business rule enforcement, and change management.
Graphical process and user interface design tools eliminate the need for extensive coding and complex APIs. Project execution shifts from managing code to managing production and standard operating procedures (SOPs).
In addition to enforcing multi-site procedural consistency, this model-driven approach brings previously isolated manual activity into the automation realm.
Who Benefits from Manufacturing Operations Management?
Effective operations delivers benefits for both operations and plant management.
Plant Engineers Can…
- Go lean – Manage work order execution by providing electronic work instructions to operators, download setup parameters to equipment, leverage governance to enforce processes and product quality, and optimise inventory levels and logistics to ensure uninterrupted production.
- Optimise asset utilisation – Monitor asset overall equipment effectiveness (OEE) and downtime events. This helps identify bottlenecks and establish best practices when comparing line-to-line and equipment-to-equipment performance effectiveness.
- Maintain quality – Enforce consistent product quality by following defined production processes, job procedures, and use of right materials to achieve specifications.
- Improve quality – Reduce waste, minimise variations, and improve yields by reducing quality giveaway using statistical process control (SPC) methods.
- Drive business performance – Are people following the same procedures and adopting best practices? Are quality variations impacting bottom-line results? Do business operations and plant operations have the real-time visibility they need to make the best planning decisions?
- Document compliance – Reduce the risk of recalls and protect your brand equity by enforcing and ensuring that products meet specifications. Document the manufacturing execution process with detailed traceability and quality records.
- See the process – Achieve supply chain visibility and decision-making support to make better planning decisions and meet customer satisfaction targets.
- Ride the wave – Facilitate closer integration of business planning and business functions with manufacturing operations to increase agility, take advantage of profitable opportunities in market demand, and optimise plant capacity.