Manufacturing Execution System (DF-MES)

1. Product Introduction
MES system is in the middle layer of a three-tier architecture, mainly facing the under manufacturing plant level,making the process characteristics very obvious. It is based on either production orders issued by the ERP system or long-term plans, through operation planning, operation scheduling, material balance, cost accounting, a quality management process to organize the production, and the reporting of ERP system data.

DFMC MES system comply complies with international MES industry standards ANSI/ISA-S95, and manufacturing execution systems (MES) national standard specification SJZ 11362-2006. With 12 functions, and 15 modules, it achieves automation of internal production process management, which has important significance to management efficiency, management activities, and management assessment.
Through production mode achieves changes in five areas:
1.1 Production is changing from passive command to real-time scheduling
1.2 Quality is changing from after sampling to on-line control
1.3 Resources is changing from passive supply to active supply
1.4 Costs is changing from after accounting to the process control
1.5 Management is changing from extensive form to quality-oriented
The program will bring office automation workflow technology into the MES system, therefore, MES systems not only provide traditional production monitoring and statistics, and report output, but also provides an activities platform for the production and management, of activities that achieve online office, online scheduling, online coordination, and online management through this platform, thereby greatly improving the efficiency of production management
2. System function
The system includes underlying data collection, process monitoring and online management, and cost assessment of related data management, to form a complete production information system. The System function module provides an automated system via the close monitoring of the underlying process of gradual transition to the business layer of cost management

2.1 Plant model establishment and basic data settings
With its core platform based on a plant module establishment, MES system defines actuating logic by combination of application functions via such as building blocks. According to physical model (real equipment, areas and pipelines, etc.) and logic model (business flow), MES system establishes plant model and provides data supports for business modules, based on plant model level in conformance to international MES industrial standard ANSI/ISA-S95.
2.2 Production process monitoring and actual production feedback
MES system places particular emphasis on monitoring of material supply between production process and technical process as well as quality index in production process. Based on real-time data in production process, it realizes real-time monitoring of manufacturing schedule, technical quality and material consumption in production departments, power-supply departments, auxiliary materials storerooms and finished products storerooms, etc by taking advantage of MES system configuration technique. The monitoring system of production process can, once discovering anything abnormal, give an alarm as per presetting, assisting production scheduling departments of enterprises for production coordination and rational scheduling for the purpose of raising quick response capability in production.
2.3 Production management
On the basis of production process monitoring, production management, guided by production planning, means organization of coordinated production, following up of data in production process and evaluation of various production indexes according to technical characteristics of different industries. production management also means optimization of production process upon data analysis and achievement of preparation of plans, follow-up, and analysis of production data as well as evaluation management thereof, etc. Therefore, managers can know real-time inputs and outputs, optimize production decisions, maximally shorten production time, reduce errors, and lower cost related to repeated manual input of data. The major functions of production management includes: production planning management, production organization, evaluation of plants, staff management and production data analysis, etc.
2.4 quipment management
Resources follow-up: equipment management, via plant model establishment, realizes resources location, information management of equipment operation standard and safe regulations, management of equipment maintenance, establishment of operators' reporting and maintenance record flow on equipment maintenance, perfection of equipment maintenance record by linking up with ERP or Asset Management System, management of equipment maintenance and point inspection follow-up.

Resource optimization: equipment running analysis; the system also can, by using equipment running data stored in automatic system, make a statistic of on/off frequencies, net running time and running load distribution (accumulative time of equipment idling, low load, normal load and over load), and make an analysis of production capability, of equipment failure rate, of equipment OEE, of equipment running record statistics, and of equipment maintenance statistics.
2.5 Equipment status monitoring
On the basis of equipment management, the system also can realize remote monitoring of equipment status, including equipment running status, key parameters change trends, equipment safety, lubrication and temperature, make a statistics of equipment running efficiency, running cost, and calculate service life of expendable parts, etc.

2.6 Production Scheduling and Contingency Response System
It is the responsibility in production scheduling to organize corporate production activity and ensure achievement of production planning. Based on the real-time information from Material Follow-up System, the system, pursuant to scheduling rules or judgments of operators, executes or modifies production planning and scheduling via automatic or human-machine interaction as well as update and issue production orders.

Contingency Response System is mainly, in the event of accidents, used for providing emergency rescue and disaster relief with emergency programme querying, accident handling expert group, human resources such as emergency-rescue group, emergency resources and simulation drill.
2.7 Quality control
MES system, according to quality control standard, makes a real-time collection of quality data from the automatic system in production fields. Once any quality problem is spotted in production process, MES system gives an alarm of abnormal quality. And production managerial staffs seek out key process link according to quality control network, or key quality staff. It has the advantages of shortening analytical process of quality problem, speeding up processing of abnormal quality, raising staffs' quality consciousness and guaranteeing products quality.

The quality control functions of MES system comprise: quality standard control, process quality control, data collection, statistic analysis of product quality and evaluation of quality indexes, etc.
2.8 Spare parts managemen
Spare parts management mainly targets at guaranteeing equipment maintenance requirement with minimal inventory, providing maintenance parts for field equipment within shortest time, and following up spare parts in their whole service life with the most normalized management. the system mainly includes the following functions:
Spare parts requirement management;
Spare parts planning management;
Spare parts track management;
Spare parts inventory management;
Spare parts consumption analysis;
2.9 Material management
Material track (process management)
MES system can, according to real-time production data collected from production lines, track the flow process of goods in progress, including: material flow, material conversion, material splitting, material combination and material consumption, etc. Users can query the information related to location and quantity of goods in progress in MES system.

MES system, with retrospective and prospective functions, can inquire which batch of raw materials and intermediary materials were used for manufacturing finished products as well as amount and features thereof, and also can inquire which finished products were manufactured from the raw materials as per their batches.
Material management (regional management)

Regional management targets at statical management of materials, including management of raw materials plan, raw materials, finished products and material stock ground, inventory management, management of raw materials consumption, etc. And it also includes, in ore beneficiation process, dead rocks management, tailings management and ore concentrate production management, etc.
2.10 Energy Management System
Energy Management System can be used for real-time monitoring of energy status in production process and for effective control of energy consumption, facilitating timely spotting crucial reasons of power waste, and timely adopting energy-saving measures, scheduling and operation, thus maximally reducing power consumption and production cost. Energy management mainly realizes automatic processing of energy-related information, analysis of tables and diagrams related to energy-related information, and dynamic query of energy-related information.

2.11 Cost control
A criss-cro cost control network is established, with management of functional departments and operation areas as key links, and with various main control processes as stagnation points, orienting weekly or even daily accounting and analysis of cost. It must make cost analysis not only for management layer but for operation areas, making first-hand data related to production cost from operation areas known to management layer for full analysis of reason for cost difference.

All-around management of cost data analysis is realized, providing statements and query for cost data and providing comparative analysis of various cost data by virtue of intuitional charts and diagrams, and saving historical data.
2.12 Safety management
Different enterprises have different emphasis requirements on safety management, and adopt different equipment and systems and Software System for Safety Management to constitute a safety-control network, for realization of safety production. Safety Management System has functions as below:
Management of environmental protection facilities archives;
Management of potential safety hazard;
Management of safety check assessment;
Disposal of accidents;
Management of safety training;
Management of radioactive source;
Management of occupational disease.
2.13 Report System
Report System is used for outputting data from subsystems of EMS system, and also serves as data interface among subsystems, being important means for integrating data source. Report forms cover all businesses of EMS system, including scheduling, equipment, quality, materials, evaluation of staff, and technical indexes, etc (also including data interface between MES system and ERP system). Data source is mainly from database of MES system. Report System reorganizes database fields via semantic layer into user-oriented objects, and based on which realizes report function.
2.14 External system integration
MES system is integrated by the systems as below
ERP system;
Production monitoring system;
Raw material system;
Auxiliary material system;
Finished stock storeroom system;
Power monitoring system;
2.15 System safety
MES system, as the mainstay in production management, shoulders very important production-organizing tasks. Therefore, it is important to guarantee safety and reliability of MES system. MES system reaches the safety and reliability mainly by the functions as below:
Storage of data redundancy by Raid5 technology;
Automatic function for periodic back-up of data;
Disaster recovery system;
Identity authentication and rights management;
High reaction speed system alarm;
System log safety record;
Firewall and virus isolation measures

3. System characteristics

3.1 Full-scale rational integration: in the development of system, top priority should be given in full-scale integration of technical process, production management activities and various production management personnel; in particular, tool-oriented integration of "human" and "production activities" should be stressed, for realization of joint management by operators and system, which is an important factor for a successful and efficient system.
3.2 To improve staffs' enthusiasm for work: the enthusiasm is the fundamental force for driving development of enterprises, so the latest systems designed by DFMC, based on statistics of the workflow, instant messaging and work efficiency, achieve step-by-step supervision of staff at every working process, cross-coordination and performance transparency, thus improving the proactiveness of staffs at every level.
3.3 Gradual accumulation of operating experience: via the executive operating system, advanced operating methods and judgment to failure due to sophisticated cause can be consolidated through the system to form a standardized and optimized method for operation of equipment and a method for controlling technical process, which not only can facilitate and simplify production operators' control activities, but also can serve as online teaching materials full of practical significance for training staff.
3.4 Complete and accurate data analysis: more and more enterprises attach great importance to collection and classification of production data. However, data use ratio is very low. Development of products by DFMC targets at making full use of every datum and of correlation among data for making more data analysis models and for providing users with accurate decision support.
3.5 Powerful work management capability: each person's work has coherence and each specific work has time-sensitive, which call for classified storage of previous work information for querying and comparison with the current work. By using the system, users can conduct well-organized management of previous work results by making additional custom category and system properties, etc. The system provides users with powerful querying and statistical data functions.
3.6 Flexible configuration of system architecture: The system uses a sophisticated "service-based SOA" enterprise software design standard, and it has the advantages of loose couple, high performance, high scalability and platformization. The system can reduce system reconfiguration risks resulting from business change in development of enterprises, being indispensable in establishment of large-scale software management systems.

4. Application

MES system developed by DFMC targets at providing solutions and services for open-air mining and underground mining, for nonferrous and ferrous metals ore beneficiation, and for industries as below: metallurgy, cement, paper-making, petrochemical, chemical, etc.

Implementation of MES system adopts integration of management and control on the selected MES system frame. Development of three-tier architecture systems, namely, ERP system, MES system and DCS system, adopts mature software platform technology. These software platforms are enterprise application platforms with high stability, high flexibility and high commonality, summarized by DFMC over many years of engineering practice and product development, serving as basic technology for DFMC to develop a variety of enterprise application software. We not only have reliable hardware devices subject to numerous tests and outstanding software systems selected from a variety of products in application, but also have a great deal of key industrial technology. These software platforms have been subject to extensive spread and exploitation with other products of DFMC nationwide. Different "workshops" of different enterprises in different industries need different versions of MES systems. Based on the MES system, in cooperation with users of specific needs, DFMC provides users with detailed MES solutions suitable for them.

It is a strong guarantee for successful implementation of the MES system to have a clear scope, a standard production management system and a long-term strategic development plan.

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