MES systems make the diagnosis to the industry

Efficiency of real time

The head of any enterprise upgrading production it is not formal, and actually, wants to see real results of purchase of the new equipment and implementation of technologies. And to learn how effective and profitable was, for example, a replacement of the old equipment or purchase of expensive process system, special programs and engineering devices are required. And not in a year or month, and in real time.

To arrange methodological, technology chaos which quite often exists at the enterprises performing transition from an old paradigm of production to new special information systems were developed. They allow to estimate efficiency rate of production at any stage and level.

What is MES? MES (Manufacturing Execution System) are production management systems. It is automation of industrial process, since the level of detailed planning of all production and finishing with the level of the machine, any technological machine, a workplace. MES systems help to solve problems of synchronization of production process, coordinate, analyze and optimize production within any production in real time.

Technology of success

How to define payback of implementation of MES? It is important to CEO, founder of the enterprise to know, expenses are how justified, the specific result which this or that technical innovation yields is important. He can say in increase in production volumes, quality improvement of products, more high demand from partners and so on.

Search of "sore points"

MES systems - that tool which allows to estimate objectively that gave to the enterprise this or that innovation: how more effectively now the equipment works, began to use it how more as losses at idle time decreased. In general thanks to MES performance increases and the equipment load factor increases; work in progress amount decreases; amounts of the stored inventory stocks decrease and the delivery adherence to deadlines improves.

Process of implementation of MES systems consists of several stages. On doproyektny the special equipment allowing to monitor process of use of technical and human resources to within a workplace, the machine is installed. It is the analysis of a status of a production system, search of "sore points". Further search of ways of implementation of MES is run.

At a post-project stage the director receives the complete, detailed picture and makes the relevant decisions. Not always the secret of industrial success is just in replacement of the equipment. It is possible to work with profit and on old. There are many factors affecting stagnation or, on the contrary, production revival: implementation of IT technologies, management, engineering.

The plant where by means of MES systems such efficiency evaluation was made, is similar to the person who underwent physical examination. If he correctly estimated the condition and listened to the recommendations of the doctor, he will be healthy.

Upgrade back

Why new technologies do not come easily?

Obviously, efficiency evaluation of production is required first of all to those enterprises which have noticeably bigger potential, than that which is used by them upon. MES systems allow to turn a production process from "a black box" into the transparent scheme.

Technologists not in the price?

Problem of change old new - eternal. Unfortunately, at present it is especially sharply endured by the domestic industry by which in 2009 the special resolution wished to be upgraded. And if equipment procurement still can do to us, then people who could exploit competently him are not enough.

- On the Russian industrial enterprises the situation when the old technology leaves remains, and new cannot come: people are not ready, structures of IT are not created, specialists did not grow up yet, - Timur Zakirov, the development director of SBE "MES" of SITEK group says. - In turn the foreman who worked all the life at the plant turns in a peculiar carrier of "sacral knowledge" which does not want to share with anybody. This some kind of reinforcement of its status. It is obvious that to train such employee in something new, besides on an equal basis with beginners, it will be very difficult.

Very often employees of the enterprise (since the lowest link, and at times even management team) not quite understand why they need to be retrained and that the specific innovation will give. In the course of upgrade of production it is necessary to face a number of system problems. It concerns also top managers.

- For Russia one of typical features - that the people who are high-class specialists in production, bad economists, - T. Zakirov considers. - And it is frequent, decisions on implementation of difficult technology projects (for example, about purchase of this or that equipment) only economists, financial directors who in it understand little accept. Their purpose - to save on production resources, i.e. to purchase not the most expensive (and, unfortunately, not the most qualitative) suitable tools. Such approach negatively affects the production: it becomes unprofitable.

Secret of "blue boxes"

MES systems are characterized by very exact and detailed analysis of a production process. That is why those stages at which there is a failure are at once opened. And if earlier the head of separate structural unit could correct the report for work before the higher management, then now he should "get into a dispute" with the indifferent machine which counts minutes of idle time. Not all people could reconcile to it.

- There were situations when employees sabotaged use of the new equipment as now amounts of completed work were counted by the computer, - T. Zakirov notes. - For example, on all machines of the plant the status light of the working tool which looks as a small blue box is installed. On a small board the condition of equipment is highlighted at present: "is included/is switched off", "work", "idle time", "breakdown" and so on. Imitate process of work on such machine at the employee just it will not turn out.

At the same time every year there are more and more heads who show interest in use of information systems in production. A positive trend - they contact suppliers of this type of service.

Alexander Struchkov, chief of the department of information technologies of JSC PKO Teploobmennik: - The staff of our enterprise passed a way from complete misunderstanding of the purposes of automation before awareness of its need in the psychological plan. About 5 years ago we started installation new, including computer, the equipment. And just now understanding on average and the lowest link appeared. He agrees that in respect of upgrade of the enterprise the leading role at the director. In many respects depends on it how executive will be subordinates. There was a time when workers promised to damage the equipment and to break the shop computer. And the new servicemen studying at the new equipment already ask whether it is possible to computerize their workplace.

In the light of Russia's accession to the World Trade Organization (in the closest and real perspective) the question of competitiveness of domestic enterprises becomes extremely sharp. And if in domestic market our products are more or less demanded (very often thanks to the state measures of support), then in the world market of such indulgences the rival countries will not give us. The considerable complexity for the Russian enterprises is represented by international quality standards which observance is impossible without implementation of the IT-systems accepted in world practice.

Automation, heads of the Nizhny Novgorod enterprises recognize, - process inevitable. A question, how fast and qualitatively it will be performed.